Support Services for Automation - SSA-1

Support Services for Automation - SSA-1
NEORSD
AUTOMATION
STANDARDS
AND
CONVENTIONS
MANUAL
Revision 2.0.1
Date: June 2, 2014
This page left blank intentionally
NEORSD AUTOMATION
STANDARDS AND CONVENTIONS MANUAL
Revision History
Revision
Revision Date
Author
Updated Section
Description
0.0.0
24-Nov-2010
PSIM
All
Compiled all individual standard documents into this
single document.
Removed Loop spreadsheets; using a hyperlink.
0.0.0
24-Nov-2010
PSIM
Part I Section 3
0.0.0
24-Nov-2010
PSIM
Part II Section 1.9
Added Deviation Request
Updated for new naming convention
0.0.0
24-Nov-2010
PSIM
Part IV Section 7
Added Process Abbreviations List
0.0.0
24-Nov-2010
PSIM
Part V
Added new sections for Wonderware and ControlLogix
and PanelView programming
0.0.1
02-Dec-2010
PSIM
Part V
Minor changes to CLX/WW standard
0.0.1
02-Dec-2010
PSIM
Part V Section 3.12
1.0.0
15-Dec-2010
PSIM
All
1.1.0
20-Jan-2011
PSIM
Part V Section 2.4, 2.7,
2.9, 2.10, 2.11
Clarification on WW platform.
1.2.0
02-Mar-2011
PSIM
Part II Section 9
Corrected section numbering.
1.2.0
02-Mar-2011
PSIM
Part II Section 1.9
1.2.0
02-Mar-2011
PSIM
Part V Section 3.4, 3.8,
3.11
Message routing, Referenced Discrete AOI, Referenced
PLC _Status AOI
1.2.0
02-Mar-2011
PSIM
Part V Section 4.3, 4.4,
4.6, 4.7, 4.8, 4.4E
Application and Display Naming, Alarms, Trends,
Default Security, Key Assignments
1.2.0
02-Mar-2011
PSIM
Part IV, Section 7
1.2.0
02-Mar-2011
PSIM
Part V Section 2.7, 2.6.D
Updates and clarifications to all sub sections, added
deadband logging
1.2.0
02-Mar-2011
PSIM
Part II Section 2.2, 2.4D,
2.4E
Added requirement for conformal coating to PLC
components and relays
1.3.0
31-May-2011
PSIM
Part II Section 7
1.3.0
31-May-2011
PSIM
Part IV Section 1.1
1.3.0
12-Jun-2011
PSIM
Part V Section 2.10.F
1.3.0
15-Jun-2011
PSIM
Part V Section 3.8D, 3.8H,
3.11D, 4.10
Clarified analog IO mapping, Digital IO mapping,
removed HMI button desc, updated diagnostics.
1.3.1
16-Jun-2011
PSIM
All
Updated revision in footer, added date and revision to
cover.
1.4.0
01-Jan-2012
PSIM
Part II Section 7
1.4.0
20-Jan-2012
PSIM
Part II Section 3.5
1.4.0
24-Jan-2012
PSIM
Part V Section 3.11.I
Added alarm horn and light acknowledgement scheme
1.4.0
24-Jan-2012
PSIM
Part V Section 2.7.J.7
Updated naming convention (was J.13)
1.4.0
24-Jan-2012
PSIM
Part V Section 2.11.E and
4.4.C
Added additional process pipe colors
1.4.0
24-Jan-2012
PSIM
Part V Section 2.7.Q.4
Added details on screen object areas
1.4.0
24-Jan-2012
PSIM
Part II Section 2.2.F
1.4.0
24-Jan-2012
PSIM
Part V Section 2.14.A.2
Added Control Modes description
Updates and clarifications to multiple sections. Includes
12/6/10 workshop comments.
Clarified use of Train & Parallel fields
Added more abbreviations to tables
Added additional abbreviations
Updated CLX wire tagging convention.
Revised WW graphic naming.
Added additional abbreviations
Added PLC5 rounding/truncation logic standard
Changed PanelViews to 120VAC with conformal coating
Added details on window scripts
NEORSD AUTOMATION
STANDARDS AND CONVENTIONS MANUAL
Revision
Revision Date
Author
Updated Section
Description
1.4.0
24-Jan-2012
PSIM
Part II Section 1.9.F
1.4.0
24-Jan-2012
PSIM
Part V Section 2.13.A.1
1.4.0
24-Jan-2012
PSIM
Part V Section 3.2
1.4.0
24-Jan-2012
PSIM
Part V Section 3.3.C
Updated module naming convention
1.4.0
24-Jan-2012
PSIM
Part V Section 3.6.F
Changed the default rate for Misc Logic
1.4.0
27-Feb-2012
PSIM
Part V Section 3.10
Updated CLX messaging standard
1.4.0
05-Mar-2012
PSIM
Part II Section 2.2.F
Update OIT specifications
1.4.0
05-Mar-2012
PSIM
Part II Section 2.4.F
Changed Stop PB to extended style
1.4.0
19-Mar-2012
PSIM
Part II Section 7
1.4.1
02-Apr-2012
PSIM
Part II Section 1.5
1.4.1
02-Apr-2012
PSIM
Part II Section 7
1.5.0
12-Jul-2012
PSIM
Part II Section 1.9
1.5.0
12-Jul-2012
PSIM
Part II Sec 2.2.B,C,D,E,F
1.5.0
05-Nov-2012
PSIM
Part II Sec 2.2
1.5.0
05-Nov-2012
PSIM
Part V Sec 2.4.A
1.5.0
05-Nov-2012
PSIM
Part V Sec 2.2,2.4,2.5,2.9
Updated assorted WW details
1.5.0
07-Dec-2012
PSIM
Part V Sec 2.2.G, 2.2.H
Added Instance naming details
1.5.0
07-Dec-2012
PSIM
Part V Section 5
1.5.0
07-Jan-2013
PSIM
Part V Sec 2.8, 3.5, 3.13
1.5.1
08-Feb-2013
PSIM
Part IV
Removed erroneous blank sections
1.6.0
12-Jun-2013
PSIM
Part V
Assorted updates per the PC&A workshop action items
1.6.1
22-Aug-2013
PJM
Part II, Section 2.2.F
Updated OIT specifications to include Notes to Specifier,
added 15 inch display, eliminated distinction between
wastewater plants and collection system, added
keypad/touch screen combination and extended features.
1.6.1
22-Aug-2013
PJM
Various sections
For clarity and consistency with Part II, Section 2.2.F,
references to “PV Plus” and “PanelView Plus” were
updated to “PV Plus 6” and “PanelView Plus 6”,
respectively. Additionally, any generic references to
“PV” or “PanelView” are also intended to mean the
“PanelView Plus 6” or current series of Allen-Bradley
OIT. Did not change “Last Edited” section date except
for Part II, Section 2.2.F where the PanelViews are
specified.
1.6.1
22-Aug-2013
PJM
Part V, Section 4.2.A
Updated OIT requirement to PanelViews with keypad
and touch screen.
1.6.1
22-Aug-2013
PJM
Part II, Section 2.2.A and
2.2.B titles
After “Allen-Bradley PLC-5” and “Rockwell SLC-500
Series” titles added “(No Longer Specified for New
Construction)”
1.6.1
22-Aug-2013
PJM
Part II, Section 2.2.C-E.1
and 2.2.C-E.2
Updated Allen-Bradley ControlLogix “removable
terminal block housings” to “extended depth removable
terminal block housings”
1.6.1
22-Aug-2013
PJM
Part II, Section 2.2.DD.3.c.1)
Fixed typo in 1492-IFM20F model number.
1.6.1
22-Aug-2013
PJM
Part II, Section 2.2.DD.3.c.2)
Added 1492-IFM40F module.
Updated examples to reflect current standard
Corrected window properties
Updated to include PLC file name
Removed Electrical standards; maintained separately
Added RS for Riverbed Street remote site
Added section 7.0 so info is show in table of contents
Removed attribute from examples; added new subsection
Updated Rockwell PLC, OIT and power supply details
Added the conformal coating requirement
Clarified default operator access allows set point changes
Added DeviceLogix standards
Clarified AOI/UDT usage
NEORSD AUTOMATION
STANDARDS AND CONVENTIONS MANUAL
Revision
Revision Date
Author
Updated Section
Description
1.6.1
22-Aug-2013
PJM
Part II, Section 6.5
1.6.1
22-Aug-2013
PJM
Part II, Sections 1.8, 3.1.F,
3.4, 4.1.A, 4.2.A, 4.3.A,
4.4, 5.0, 5.1, 5.1.A, 5.2.A,
5.2.B, 5.2.C, 5.2.F, 5.2.G,
5.3, 5.3.A, 5.3.B, 5.4,
5.4.A, 6.5, 6.6, 6.7
Updated District contact person for Automation updates
from Jim Klosz and Scott Sander to “the Manager of
Process Control & Automation”. Did not change “Last
Edited” section date for affected sections unless other text
within the section was revised.
1.6.1
22-Aug-2013
PJM
Part II, Section 9.1
Separated instrument tag formats by treatment plant and
collection system. Added control valves to instrument tag
format.
1.6.1
22-Aug-2013
PJM
Part II, Section 9.1
Added panel tag format for treatment plants and for
collection system
1.6.1
22-Aug-2013
PJM
Part II, Section 9.1.B
Add Area 20 for Aerated Grit Facility to Easterly process
area number list.
1.6.1
22-Aug-2013
PJM
Part IV, Section 7.0
Added abbreviations for “Grease” and “Object Trap”.
2.0.0
25-Mar-2014
Westin
Part I All Sections
Extensive revisions – See revisions below for a summary
of the major changes. See Revision 1.6.1 for above
referenced revisions. Section numbering changed in
Revision 2.0.0
2.0.0
25-Mar-2014
Westin
Part I
Revised the NEORSD Standards Deviation Request Form
2.0.0
25-Mar-2014
Westin
Part II
Deleted all information about the GE Cimplicity legacy
HMI system. Included in the deletions was Section 1.2 –
Standard Cimplicity Screen Templates, Section 1.5 –
Point Tag Naming Convention.
2.0.0
25-Mar-2014
Westin
Part II
Added new section – Process Control and Automation
System Design Support Documentation.
2.0.0
25-Mar-2014
PJM
Part II
Deleted sections on legacy PLCs for Allen-Bradley PLC5 and SLC-500.
2.0.0
25-Mar-2014
PJM
Part II
Section 2.2.D – For Rockwell CompactLogix PLC,
deleted connection adapter, cable, and IFM because
interposing terminal blocks are specified.
2.0.0
25-Mar-2014
PJM
Part II
Section 2.2.F – Changed OIT (PanelView) power to 24
VDC because conformal coating is not available for 120
VAC-powered OITs. Changed “A” in OIT catalog
numbers to “D” for DC power.
2.0.0
25-Mar-2014
Westin
Part II
Section 2.2G
Programming”
2.0.0
25-Mar-2014
Westin
Part II
Section 9.2 – System Integrator
2.0.1
02-Jun-2014
NEORSD
Entire Document
Added cellular for pump station communications.
–
Revised
section
“Software
Reformatted entire document for consistency.
and
NEORSD AUTOMATION
STANDARDS AND CONVENTIONS MANUAL
Revision
Revision Date
Author
Updated Section
Description
Revision Format: X.Y.Z
• X = Major modifications to any section of the document. These types of changes effect functionality or
operation of a process. Adding or deleting sections also constitutes a major change. This level of change
requires a review and approval by subject matter experts.
• Y = Intermediate modification to any section of the document. Typically a clarification to an existing section.
This level of change requires a review and approval by subject matter experts.
• Z = Minor change to a proposed revision. Example: 1.1.0 is submitted for review, and a spelling error is caught.
The document is revised up to 1.1.1 and continued through the review cycle. It is not necessary to go back to
previous subject matter experts for a second review.
NEORSD AUTOMATION
STANDARDS AND CONVENTIONS MANUAL
TABLE OF CONTENTS
Part I - Background ....................................................................................................................... I-1
Section 1 - Overview ................................................................................................................. I-1
Section 2 - Purpose .................................................................................................................... I-1
Section 3 – Standards Deviation Request .................................................................................. I-2
Section 3.0 - General ............................................................................................................. I-2
Section 3.1 - Procedure .......................................................................................................... I-3
Part II - Standards and Conventions ........................................................................................... II-1
Section 1 - HMI Standards and Conventions .......................................................................... II-1
Section 1.0 - Introduction .................................................................................................... II-1
Section 1.1 - Process Symbols and Color Conventions ....................................................... II-1
Section 1.2 - Standard Cimplicity Screen Templates .......................................................... II-3
Section 1.3 - Alarm Priorities .............................................................................................. II-8
Section 1.4 - Alarm Configuration ...................................................................................... II-9
Section 1.5 - Point Tag Naming Convention ...................................................................... .II-9
1.5.A - Existing Process Loops for Easterly WWTP ........................................................ II-9
1.5.B - Existing Process Loops for Westerly WWTC ...................................................... II-9
1.5.C - Existing Process Loops for Southerly WWTC ..................................................... II-9
1.5.D - Existing Process Loops for Remote Pump Stations ............................................. II-9
Section 1.6 - Process Control............................................................................................. II-10
Section 1.7 - Process Control and Automation System Design Support Documentation..II-11
Section 1.8 - Custom Programming................................................................................... II-12
Section 1.9 - Reporting Point Changes .............................................................................. II-13
Section 1.10 - Tag Naming Formats for CLX/WW/PV+ .................................................. II-14
1.10.A - General .............................................................................................................. II-14
1.10.B - Format ............................................................................................................... II-14
1.10.C - Object Attributes ............................................................................................... II-16
1.10.D - Process, Equipment & Parameter Names ......................................................... II-17
1.10.E - Example Tag Names ......................................................................................... II-17
1.10.F - Format for Description Field ............................................................................. II-18
1.10.G - Other Requirements .......................................................................................... II-18
Section 2 - PLC Panel Construction Standards ..................................................................... II-19
Section 2.0 - Introduction .................................................................................................. II-19
Section 2.1 - Panel Construction ....................................................................................... II-19
Section 2.2 - PLC Hardware & Software .......................................................................... II-29
2.2.A - Allen-Bradley PLC-5 (No Longer Specified for New Construction)………….II-29
2.2.B - Rockwell SLC-500 Series (No Longer Specified for New Construction)..........II-29
2.2.C - Rockwell ControlLogix ...................................................................................... II-29
2.2.D - Rockwell CompactLogix .................................................................................... II-33
2.2.E - Rockwell Packaged CompactLogix with Embedded I/O.................................... II-36
2.2.F - Operator Interface Terminals (OIT): ................................................................... II-37
2.2.G - Software and Programming: ............................................................................... II-39
Section 2.3 - Panel Wiring ................................................................................................. II-40
NEORSD AUTOMATION
STANDARDS AND CONVENTIONS MANUAL
2.3.A - Wire Types: ........................................................................................................ II-40
2.3.B - Color Standards ................................................................................................... II-41
2.3.C - Wiring Separation Distances............................................................................... II-41
2.3.D - Wire Tagging and Labeling ................................................................................ II-41
2.3.E - Grounding ........................................................................................................... II-42
Section 2.4 - Panel Components ........................................................................................ II-43
2.4.A - Power Distribution Terminal Blocks .................................................................. II-43
2.4.B - Terminal Blocks .................................................................................................. II-43
2.4.C - Fused Terminal Blocks ....................................................................................... II-43
2.4.D - Control Relays .................................................................................................... II-44
2.4.E - Timing Relays ..................................................................................................... II-45
2.4.F - Panel-Mounted Operators and Pilot Lights ......................................................... II-45
Section 3 - PLC Programming Standards .............................................................................. II-48
Section 3.0 - Introduction .................................................................................................. II-48
Section 3.1 - Allen Bradley PLC 5 Programming Conventions ........................................ II-48
3.1.A - I/O Ranges .......................................................................................................... II-48
3.1.B - Block Transfer Ranges ........................................................................................ II-48
3.1.C - HMI Polling Files ............................................................................................... II-48
3.1.D - Remote I/O Addressing ...................................................................................... II-49
3.1.E - Flex I/O Addressing ............................................................................................ II-49
3.1.F - Software............................................................................................................... II-49
Section 3.2 - Allen-Bradley SLC 500 Programming Conventions.................................... II-50
Section 3.3 - Allen Bradley Operator Interface ................................................................. II-50
Section 3.4 - Other PLC Programming Conventions ........................................................ II-50
Section 3.5 - Analog Rounding/Truncation Logic ............................................................ II-51
3.5.A - General ................................................................................................................ II-51
3.5.B - Background ......................................................................................................... II-51
3.5.C - General Solution ................................................................................................. II-52
3.5.D - Implementation ................................................................................................... II-53
3.5.E - Ladder Logic – Printed........................................................................................ II-56
Section 4 - Computer Hardware ............................................................................................ II-59
Section 4.0 - Introduction .................................................................................................. II-59
Section 4.1 - Area Control Stations (ACS, Viewer) .......................................................... II-59
4.1.A - Computer System ………………………………………………………………II-59
4.1.B-Monitor…………………………………………………………………………..II-60
4.1.C - Keyboard ............................................................................................................. II-60
4.1.D - Enclosure ............................................................................................................ II-60
4.1.E - Installation Details .............................................................................................. II-60
Section 4.2 - Area Control Station/Servers (ACS/S) ......................................................... II-61
4.2.A - Computer System................................................................................................ II-61
4.2.B - Monitor ............................................................................................................... II-61
4.2.C - Keyboard ............................................................................................................. II-62
4.2.D - Enclosure ............................................................................................................ II-62
4.2.E - Installation Details .............................................................................................. II-62
Section 4.3 - Historians and Domain Controllers .............................................................. II-63
4.3.A - Computer System................................................................................................ II-63
NEORSD AUTOMATION
STANDARDS AND CONVENTIONS MANUAL
4.3.B - Monitor ............................................................................................................... II-63
4.3.C - Keyboard ............................................................................................................. II-63
4.3.D - Enclosure ............................................................................................................ II-63
Section 4.4 - Printers.......................................................................................................... II-64
4.4.A - Report Printer...................................................................................................... II-64
4.4.B - Alarm Printer ...................................................................................................... II-64
4.4.C - Graphics Printer .................................................................................................. II-64
4.4.D - Mid-size Format Graphics Printer ...................................................................... II-64
Section 5 - Software .............................................................................................................. II-65
Section 5.0 - Introduction .................................................................................................. II-65
Section 5.1 - Computer / Network Operating System ....................................................... II-65
5.1.A - Requirements ...................................................................................................... II-65
5.1.B - Group Management ............................................................................................ II-66
5.1.C - Security Measures ............................................................................................... II-66
Section 5.2 - Drivers / Utilities Software........................................................................... II-66
5.2.A - ODBC Database Drivers..................................................................................... II-66
5.2.B - Hardware Drivers ................................................................................................ II-66
5.2.C - Anti-Virus Software ............................................................................................ II-66
5.2.D - Printer Drivers .................................................................................................... II-67
5.2.E - Intranet Browser .................................................................................................. II-67
5.2.F - Backup Software ................................................................................................. II-67
5.2.G - PLC Communications Drivers ............................................................................ II-67
Section 5.3 - HMI Software ............................................................................................... II-68
5.3.A - Base Product ....................................................................................................... II-68
5.3.B - Additional Applications Modules ....................................................................... II-68
Section 5.4 - Relational Database ...................................................................................... II-69
5.4.A - Base Product ....................................................................................................... II-69
5.4.B - Interface to ODMS .............................................................................................. II-69
5.4.C - Interface for HMI Trends .................................................................................... II-69
5.4.D - Interface for HMI Historical and Alarm Logs .................................................... II-69
5.4.E - Table Structure .................................................................................................... II-69
5.4.F - Query Structure (Section to be completed) ......................................................... II-69
Section 6 - Communication Standards .................................................................................. II-70
Section 6.0 - Introduction .................................................................................................. II-70
Section 6.1 - Control Network LAN Design ..................................................................... II-70
6.1.A - Topology ............................................................................................................. II-70
6.1.B - Monitoring / Management .................................................................................. II-70
Section 6.2 - Control Network WAN Design .................................................................... II-71
6.2.A - Topology ............................................................................................................. II-71
6.2.B - Frame Relay Interface ......................................................................................... II-71
Section 6.3 - LAN / WAN Hardware ................................................................................ II-71
6.3.A - Switches .............................................................................................................. II-71
6.3.B - Routers ................................................................................................................ II-71
6.3.C - Media Converters and Transceivers.................................................................... II-71
Section 6.4 - TCP / IP Protocol ......................................................................................... II-72
6.4.A - Numbering system and ranges ............................................................................ II-72
NEORSD AUTOMATION
STANDARDS AND CONVENTIONS MANUAL
Section 6.5 - Pump Station Communication...................................................................... II-72
6.5.A - Modem ................................................................................................................ II-73
6.5.B - Dedicated Leased Lines ...................................................................................... II-73
Section 6.6 - Remote Collection System Site Modem Communication............................ II-73
Section 6.7 - Remote Collection System Site Radio Communication............................... II-73
Section 7 - Electrical Standards ............................................................................................. II-73
Section 7.0 - See NEORSD Engineering and Construction Department .......................... II-73
Section 8 - CCTV System ..................................................................................................... II-74
Section 8.0 - Introduction .................................................................................................. II-74
Section 8.1 - CCTV Equipment ......................................................................................... II-74
8.1.A - Color Cameras: ................................................................................................... II-74
8.1.B - Camera Housing: ................................................................................................ II-75
8.1.C - Pan and Tilt Drive: .............................................................................................. II-75
8.1.D - Camera Mounting Brackets: ............................................................................... II-76
8.1.E - Receiver: ............................................................................................................. II-76
8.1.F - Surge Protection: ................................................................................................. II-77
8.1.G - Cables: ................................................................................................................ II-77
8.1.H - Video Camera Transceiver Links: ...................................................................... II-77
8.1.I - System Controller:................................................................................................ II-77
8.1.J - Monitors: .............................................................................................................. II-78
8.1.K - Digital Multiplexers: ........................................................................................... II-79
8.1.L - Video Cassette Recorder (VCR): ........................................................................ II-80
Section 9 - Instrumentation, System Integration, and Testing .............................................. II-81
Section 9.0 - Introduction .................................................................................................. II-81
Section 9.1 - Instrument and Panel Tagging...................................................................... II-81
9.1.A - Westerly Wastewater Treatment Center ............................................................. II-84
9.1.B - Easterly Wastewater Treatment Center .............................................................. II-86
9.1.C - Southerly Wastewater Treatment Center ............................................................ II-88
Section 9.2 - System Integrator ......................................................................................... II-90
9.2.A - Summary ............................................................................................................. II-90
9.2.B - System Integrator’s Qualifications ..................................................................... II-90
9.2.C - System Integrator’s Responsibilities................................................................... II-91
9.2.D - System Integrator’s Project Personnel ................................................................ II-92
9.2.E - Factory Acceptance testing ................................................................................. II-92
9.2.F - System Checkout, Startup, and Commissioning Responsibilities..................... II-93
9.2.G - Integrity Testing.................................................................................................. II-94
9.2.H - Calibration .......................................................................................................... II-95
9.2.I - System Checkout and Startup .............................................................................. II-95
9.2.J - Commissioning .................................................................................................... II-96
9.2.K - Loop Verification................................................................................................ II-96
9.2.L - Functional Performance Testing (FPT) ............................................................... II-97
9.2.M - Re-commissioning ............................................................................................. II-98
9.2.N - Availability testing.............................................................................................. II-98
9.2.O - Instrument certification sheet ............................................................................. II-98
9.2.P - Final Control Element Certification Sheet ........................................................ II-100
9.2.Q - Control Loop Checkout Sheet .......................................................................... II-103
NEORSD AUTOMATION
STANDARDS AND CONVENTIONS MANUAL
9.2.R - Checkout Certification Sheet…………………………………………… …..II-105
9.2.S - Component Settings Record…………………………………………………..II-106
Part III - Control Network.......................................................................................................... III-1
Section 1 - Easterly WWTP Network Block Diagram ........................................................... III-1
Section 2 - Southerly WWTC Network Block Diagram ........................................................ III-2
Section 3 - Westerly WWTC Network Block Diagram ......................................................... III-3
Part IV - Appendices .................................................................................................................. IV-4
Section 1 - Wire Tagging and Numbering Convention .......................................................... IV-4
Section 1.0 - PLC-5 Wire Tagging and Numbering Convention ....................................... IV-4
Section 1.1 - ControlLogix Wire Tagging Convention ...................................................... IV-5
Section 2 - Sample Control Schematic with PLC-5 Wire Tagging ........................................ IV-6
Section 3 - PLC-5 Panel Sample Interposing Terminal Wire Tagging .................................. IV-7
Section 4 - Sample PLC-5 Enclosure Layout Drawings ........................................................ IV-8
Section 5 - Sample PLC-5 Digital I/O Wiring Drawing ...................................................... IV-14
Section 6 - Sample PLC-5 Analog I/O Wiring Drawing ...................................................... IV-15
Section 7 - Process, Equipment, and Parameter Abbreviations ........................................... IV-16
Section 7.0 - Process Abbreviations ................................................................................. IV-16
Section 7.1 - Equipment Abbreviations ............................................................................ IV-19
Section 7.2 - Parameter Abbreviations ............................................................................. IV-22
Part V - ControlLogix / Wonderware / PanelView Plus 6 .......................................................... V-1
Section 1 - Introduction ......................................................................................................... V-11
Section 2 - Wonderware Standards and Conventions ............................................................. V-2
Section 2.0 - Introduction .................................................................................................... V-2
Section 2.1 - Wonderware ArchestrA Key Concepts .......................................................... V-2
Section 2.2 - Simplified Network Architecture ................................................................... V-3
Section 2.3 - Software.......................................................................................................... V-3
2.3.A - New Applications ................................................................................................. V-3
Section 2.4 - Security Design .............................................................................................. V-4
2.4.A - Platform / Application Security ............................................................................ V-4
2.4.B - ArchestrA Role – Default ..................................................................................... V-4
2.4.C - ArchestrA Role – 18_Opers .................................................................................. V-5
2.4.D - ArchestrA Role – 2798_Opers.............................................................................. V-5
2.4.E - ArchestrA Role – Facility_Managers.................................................................... V-5
2.4.F -ArchestrA Role–HMI Programmers/Domain Programmers/REF_Programmers.V-66
2.4.G - ArchestrA Role – Administrator/Administrators.................................................. V-7
2.4.H - Common Functions (InTouch) ............................................................................. V-7
2.4.I - Electronic Records ................................................................................................. V-7
Section 2.5 - Communication Design .................................................................................. V-7
2.5.A - ArchestrA IDE ...................................................................................................... V-7
2.5.B - Model View .......................................................................................................... V-8
2.5.C - Managed InTouch Application ............................................................................. V-8
2.5.D - Data Collection ..................................................................................................... V-8
2.5.E - Tag Naming Standards .......................................................................................... V-8
Section 2.6 - Base Template Library (BTL) ........................................................................ V-8
2.6.A - Introduction........................................................................................................... V-9
2.6.B - BTL Input Source Scripts ..................................................................................... V-9
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2.6.C - BTL Script Locations .......................................................................................... V-10
2.6.D - Data Logging Deadband ..................................................................................... V-10
Section 2.7 - Platform Templates ...................................................................................... V-11
2.7.A - $AlarmSummary................................................................................................. V-11
2.7.B - $EngineForAlmLogService ................................................................................ V-17
2.7.C - $Historian............................................................................................................ V-20
2.7.D - MenuBar ............................................................................................................. V-21
2.7.E - $NEORSDAOS ................................................................................................... V-23
2.7.F - NEORSDAppEngine ........................................................................................... V-26
2.7.G - $NEORSDArea_Lower ...................................................................................... V-28
2.7.H - $NEORSDArea_Top .......................................................................................... V-29
2.7.I - $NEORSDClient .................................................................................................. V-30
2.7.J - $NEORSDDDESuiteLinkClient .......................................................................... V-31
2.7.K - $NEORSDDDESuiteLinkClient_HIS ................................................................ V-34
2.7.L - $NEORSDGR ..................................................................................................... V-36
2.7.M - $NEORSDUserDefined ..................................................................................... V-37
2.7.N - $NEORSDViewEngine ...................................................................................... V-38
2.7.O - $NEORSDWinPlatform ..................................................................................... V-39
2.7.P - $PrinterSelect ...................................................................................................... V-41
2.7.Q - $Screen_Object ................................................................................................... V-43
Section 2.8 - Device Object Template Library .................................................................. V-43
Section 2.9 - InTouch Application..................................................................................... V-44
2.9.A - $NEORSD_View (managed InTouch App) ....................................................... V-44
2.9.B - Description .......................................................................................................... V-44
2.9.C - Functional Details ............................................................................................... V-44
2.9.D - Condition Scripts ................................................................................................ V-44
2.9.E - Data Change Scripts ............................................................................................ V-44
2.9.F - QuickFunctions ................................................................................................... V-44
2.9.G - InTouch System Windows.................................................................................. V-45
Section 2.10 - General Coding Practices ........................................................................... V-46
2.10.A - Scripting Code Comment Guidelines ............................................................... V-46
2.10.B - Scripting Code Headers .................................................................................... V-46
2.10.C - Scripting Code Structure Practices ................................................................... V-47
2.10.D - Dead Code ........................................................................................................ V-47
2.10.E - ArchestrA Device Object Instances .................................................................. V-47
2.10.F - Window Naming Convention............................................................................ V-48
Section 2.11 - Display Guidelines ..................................................................................... V-49
2.11.A - General .............................................................................................................. V-49
2.11.B - Common............................................................................................................ V-49
2.11.C - Lines .................................................................................................................. V-49
2.11.D - Text Guideline .................................................................................................. V-50
2.11.E - Pipes (InTouch vs ArchestrA) ........................................................................... V-50
2.11.F - Standard Static Process Symbols ...................................................................... V-52
2.11.G - Locations........................................................................................................... V-52
2.11.H - Common Symbols ............................................................................................ V-52
Section 2.12 - Standard Symbols ....................................................................................... V-52
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2.12.A - Locations........................................................................................................... V-52
2.12.B - Common Features ............................................................................................. V-52
Section 2.13 - Windows ..................................................................................................... V-53
2.13.A - Adding New Windows ..................................................................................... V-53
2.13.B - Navigation ......................................................................................................... V-53
2.13.C - Site Specific – Southerly................................................................................... V-54
2.13.D - Site Specific – Easterly ..................................................................................... V-55
2.13.E - Site Specific – Westerly .................................................................................... V-56
Section 3 - ControlLogix Programming Conventions ........................................................... V-57
Section 3.0 - Introduction .................................................................................................. V-57
3.0.A - General Programming......................................................................................... V-57
Section 3.1 - Firmware Revision ....................................................................................... V-57
3.1.A - Controller Firmware Revision ............................................................................ V-57
3.1.B - Control Module Firmware Revision ................................................................... V-57
Section 3.2 - Controller Naming ........................................................................................ V-58
Section 3.3 - Controller I/O ............................................................................................... V-58
3.3.A - I/O Distribution................................................................................................... V-58
3.3.B - I/O Electronic Keying ......................................................................................... V-58
3.3.C - I/O Module and Remote Rack Naming .............................................................. V-59
3.3.D - I/O Usage in Logic.............................................................................................. V-59
Section 3.4 - Controller to Controller Communication ..................................................... V-60
3.4.A - Message Instructions .......................................................................................... V-60
3.4.B - Produce/Consume ............................................................................................... V-60
Section 3.5 - Controller Tags ............................................................................................. V-60
3.5.A - Tag Naming ........................................................................................................ V-60
3.5.B - Tag Scope............................................................................................................ V-60
3.5.C - Aliasing ............................................................................................................... V-60
3.5.D - User-Defined Data Types (UDTs) ...................................................................... V-61
Section 3.6 - Task Structure............................................................................................... V-61
3.6.A - Task Usage.......................................................................................................... V-61
3.6.B - General Periodic Tasks ....................................................................................... V-61
3.6.C - PID Control Task ................................................................................................ V-61
3.6.D - I/O Mapping Task ............................................................................................... V-62
3.6.E - Process Control Task........................................................................................... V-62
3.6.F - Miscellaneous Logic............................................................................................ V-62
3.6.G - General Event Tasks ........................................................................................... V-62
3.6.H - Unscheduled Programs and Inhibited Tasks....................................................... V-62
Section 3.7 - Standard Program Structure ......................................................................... V-62
3.7.A - General ................................................................................................................ V-62
3.7.B - PID Control Programs......................................................................................... V-62
3.7.C - Process Control Programs ................................................................................... V-62
3.7.D - I/O Mapping Program ......................................................................................... V-63
3.7.E - Miscellaneous Alarms ......................................................................................... V-63
Section 3.8 - Standard Routine Structure .......................................................................... V-63
3.8.A - General ................................................................................................................ V-63
3.8.B - Main Routine ...................................................................................................... V-63
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3.8.C - I/O Mapping Routines......................................................................................... V-63
3.8.D - Analog I/O .......................................................................................................... V-63
3.8.E - Digital I/O ........................................................................................................... V-64
3.8.F - Network I/O ......................................................................................................... V-66
3.8.G - Message I/O ........................................................................................................ V-66
3.8.H - General Alarms ................................................................................................... V-66
3.8.I - PID Loops ............................................................................................................ V-67
3.8.J - Process Control Routines ..................................................................................... V-67
Section 3.9 - Initialization Logic ....................................................................................... V-67
3.9.A - General ................................................................................................................ V-67
3.9.B - Initialize Routine................................................................................................. V-67
Section 3.10 - Message Instruction Guidelines ................................................................. V-68
3.10.A - General .............................................................................................................. V-68
3.10.B - Organization...................................................................................................... V-68
3.10.C - Peer Messaging Guidelines ............................................................................... V-69
Section 3.11 - General Coding Guidelines ........................................................................ V-79
3.11.A - Commenting Logic ........................................................................................... V-79
3.11.B - Indirect Addressing ........................................................................................... V-79
3.11.C - Subroutine Nesting............................................................................................ V-79
3.11.D - Output Instructions ........................................................................................... V-79
3.11.E - Function Block Sheets....................................................................................... V-79
3.11.F - Simulation of Logic ........................................................................................... V-80
3.11.G - Fault Resets ....................................................................................................... V-80
3.11.H - Forced Logic ..................................................................................................... V-80
3.11.I - Alarm Horn and Light Acknowledging ............................................................. V-81
Section 3.12 - General Control Mode Philosophy ............................................................. V-82
3.12.A - Local Control Modes ........................................................................................ V-82
3.12.B - Remote Control Mode....................................................................................... V-82
3.12.C - Control Mode Functions ................................................................................... V-83
Section 3.13 - Add On Instruction (AOI) .......................................................................... V-83
3.13.A - Usage ................................................................................................................ V-83
3.13.B - Source Protection .............................................................................................. V-83
Section 4 - PanelView Plus 6 Programming Conventions .................................................... V-84
Section 4.0 - Introduction .................................................................................................. V-84
Section 4.1 - Software........................................................................................................ V-84
Section 4.2 - Standard PanelView Framework .................................................................. V-84
4.2.A - Overview............................................................................................................. V-84
4.2.B - Standardized Objects and Functions ................................................................... V-84
Section 4.3 - Project Settings ............................................................................................. V-85
4.3.A - PanelView Application Name ............................................................................ V-85
4.3.B - Project General Settings ...................................................................................... V-85
4.3.C - Project Runtime Settings..................................................................................... V-86
4.3.D - Internal Clock Synchronization .......................................................................... V-86
4.3.E - Other Global Connections ................................................................................... V-86
4.3.F - MER Files............................................................................................................ V-86
Section 4.4 - Display Development ................................................................................... V-87
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4.4.A - Display Type ....................................................................................................... V-87
4.4.B - Display Name...................................................................................................... V-87
4.4.C - Color Standards ................................................................................................... V-88
4.4.D - Font ..................................................................................................................... V-89
4.4.E - Navigation ........................................................................................................... V-90
4.4.F - OEM Screens ....................................................................................................... V-96
Section 4.5 - Tag References and Usage ........................................................................... V-96
4.5.A - Direct Reference Tags ........................................................................................ V-96
4.5.B - HMI Tags ............................................................................................................ V-96
Section 4.6 - Security......................................................................................................... V-97
4.6.A - User Groups and Accounts ................................................................................. V-97
4.6.B - General Account Privileges and Restrictions ..................................................... V-97
4.6.C - Configuring Security Access .............................................................................. V-99
4.6.D - Account Login/Logout........................................................................................ V-99
4.6.E - Auto Logout ........................................................................................................ V-99
Section 4.7 - Alarming..................................................................................................... V-100
4.7.A - Trigger Type ..................................................................................................... V-100
4.7.B - Trigger Tag ....................................................................................................... V-100
4.7.C - ControlLogix Trigger Routine .......................................................................... V-100
4.7.D - Trigger Label .................................................................................................... V-100
4.7.E - Message Guidelines .......................................................................................... V-100
4.7.F - Advanced Settings ............................................................................................. V-101
4.7.G - Alarm Displays ................................................................................................. V-102
4.7.H - Alarm Filtering ................................................................................................. V-102
Section 4.8 - Trending ..................................................................................................... V-103
4.8.A - Trend Areas ...................................................................................................... V-103
4.8.B - Trend Area Template ........................................................................................ V-103
4.8.C - Other Trends ..................................................................................................... V-103
4.8.D - Trend Colors ..................................................................................................... V-103
4.8.E - Refresh Rate ...................................................................................................... V-104
4.8.F - Trend History .................................................................................................... V-104
4.8.G - Maximum Pens per Trend ................................................................................ V-104
4.8.H - Other Trend Settings ......................................................................................... V-104
Section 4.9 - Data Logging .............................................................................................. V-105
4.9.A - Number of Models ............................................................................................ V-105
4.9.B - Maximum Data Points ...................................................................................... V-105
4.9.C - Logging Path ..................................................................................................... V-105
4.9.D - Log Triggers ..................................................................................................... V-105
4.9.E - Tags In Model ................................................................................................... V-105
Section 4.10 - IO Diagnostic Screens .............................................................................. V-106
4.10.A - Overview......................................................................................................... V-106
4.10.B - Screen Requirements and Architecture ........................................................... V-106
4.10.C - Area and Navigation ....................................................................................... V-107
Section 4.11 - Standard Control Templates ..................................................................... V-108
4.11.A - Global Object Templates ................................................................................ V-108
4.11.B - General Usage Requirements .......................................................................... V-108
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4.11.C - Global Object Default Values ......................................................................... V-109
Section 5 - DeviceLogix Programming ............................................................................... V-110
Section 5.0 - Introduction ................................................................................................ V-110
Section 5.1 - Programming for DeviceNet ...................................................................... V-110
5.1.A - General .............................................................................................................. V-110
5.1.B - Software ............................................................................................................ V-110
5.1.C - Revisions ........................................................................................................... V-110
Section 5.2 - Standard Program Structure ....................................................................... V-111
5.2.A - Logic Routines .................................................................................................. V-111
5.2.B - Node Address .................................................................................................... V-111
5.2.C - Network Communication Speed ....................................................................... V-111
5.2.D - Commenting Logic ........................................................................................... V-111
5.2.E - EDS Files .......................................................................................................... V-111
Section 5.3 - Standard Program Naming Conventions .................................................... V-111
5.3.A - RSNetWorx Program Naming Convention ...................................................... V-111
5.3.B - Device Naming Convention.............................................................................. V-112
5.3.C - DeviceLogix Program ....................................................................................... V-113
Section 5.4 - Standard Ladder Editor Commenting Conventions ................................... V-115
5.4.A - Ladder Commenting ......................................................................................... V-115
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Part I
BACKGROUND
SECTION 1 - OVERVIEW
The Northeast Ohio Regional Sewer District (NEORSD, or the District) is a political subdivision
of the State of Ohio. It was established to provide services for collection, conveyance and
treatment of wastewater for most of the greater Cleveland Metropolitan Area. The service area
encompasses the City of Cleveland and all or portions of 61 suburban municipalities in
Cuyahoga, Summit, Lake and Lorain Counties and includes service to a diversified group of
manufacturing and processing industries.
The mission of the District is to provide effective wastewater and stormwater management that
protects the health and environment of the region while enhancing quality of life. Since its
creation, the District has planned, designed, constructed, operated, and maintained wastewater
collection and wastewater treatment facilities and assets throughout its service area.
The District operates three wastewater treatment plants; the Southerly Wastewater Treatment
Center, Easterly Wastewater Treatment Plant and Westerly Wastewater Treatment Center, and
an extensive wastewater collection system that conveys wastewater and stormwater to the
treatment plants. Through the operation of these plants and controlled use of wastewater storage
capacity in the collection system, the District protects public health and enhances the water
quality of Lake Erie and the Cuyahoga River.
Widespread application of instrumentation and process automation is an essential aspect of
improving the efficiency and effectiveness of the District’s operations. The District’s continuing
process automation initiative aims at providing an integrated, state-of-the-art, process monitoring
and control system. The District has established the Process Control and Automation (PC&A)
Department to provide expertise and services to maintain and manage the process control and
automation system. The PC&A and Engineering & Construction Departments have established
design, configuration and implementation standards to enable the District to manage the overall
uniformity, compatibility and quality of control system hardware, software, instrumentation,
communications and documentation.
SECTION 2 - PURPOSE OF THIS MANUAL
Wherever possible, process control system design, implementation and components, including
hardware, software, communications, programming, and supporting mechanical and electrical
design and equipment must adhere to NEORSD standards. Standardization provides a number of
benefits including improved buying power, reduced spare parts inventory, easier/reduced training
requirements, better overall performance, and uniform operation and maintenance
As part of the overall effort to achieve consistent, compatible, and reliable implementation of
instrumentation and control systems throughout the District’s wastewater collection and
treatment facilities, the District has developed this NEORSD Automation Standards and
Conventions Manual, and has also compiled a collection of instrumentation and control
templates, guidelines, design standards, and standard specifications. These documents are based
on best practices and examples of successful system development under various District projects.
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Content is continuously being added and updated in an effort to maintain and up-to-date and
expanding library of Process Control and Automation Standards.
The District’s goal is to ultimately have a complete set of standards that are accessible to those
that need them for carrying out District instrumentation, control and automation system work.
In-house designers and technicians, design consultants, system integrators and constructors are
expected to incorporate and follow the standards when creating, deploying and/or upgrading all
aspects of the District-wide process control and automation system. Process control and
automation standards are to be applied when designing or implementing changes or additions to
control and monitoring of the connected process equipment or to the process control and
automation system itself.
One of the District’s most important goals is to ensure all control processors and operator
interfaces conform to a common product platform, and in doing so produce control logic,
databases, reports, displays and other system components that are fully aligned with the needs of
the District’s current facilities and operations. Copying or transferring control logic and other
programming from the existing system will not be acceptable unless specifically required by
contract specifications. The standards included in this manual as well as the District’s other
design standards must be adhered to in developing, programming and documenting control
strategies and other system features.
SECTION 3 - STANDARDS DEVIATION REQUEST
Section – 3.0 - General
The NEORSD Automation Standards and Conventions are intended to provide consistent,
reliable controls within all plants. However, it is recognized that there may be specific instances
in which a contractor or supplier may not be able to fully comply with the standards for software,
equipment, cabling and other control system components supplied or developed under a contract
or other procurement method, or may not be able to program or configure the system in
conformance with these standards. When these cases arise, the contractor or supplier must
submit a request for deviation from NEORSD Standards using the NEORSD Standards
Deviation Request Form included in this section. The District will review the issues documented
on the form and any supplemental documentation that is supplied with the request, and if
compelling reasons are presented, the District may grant the deviation. The Standards Deviation
Request must meet the following criteria:
1. It must clearly indicate those sections of the standards that are relevant to the proposed
deviation(s)
2. It must verify that compliance with the standards from which the deviation(s) is requested
is, under the circumstances, not feasible
3. It must explain how the deviation(s) meets the fundamental intent of the Standards and the
project requirements
4. It must include a specific description of the proposed alternative to the requirements in the
NEORSD Standards and include supporting documentation. Documentation may include
references demonstrating successful use by other public utilities
5. It must show that such deviations are not contrary to the public interest, health and safety
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6. It must verify that the deviation(s) will not compromise safety, functionality, public health,
esthetics, and maintainability
7. It must verify that all applicable codes will be met.
Section – 3.1 - Procedure
The process to request a deviation from the NEORSD Automation Standards and Conventions is
as follows:
1. Fill out and submit the NEORSD Standards Deviation Request Form. The form must be
filled out electronically and submitted via e-mail to the designated NEORSD Project
Manager or other designated contact. NEORSD will supply the blank electronic form on
request. A copy of the form is included in this section.
2. Transmit supporting documentation, such as drawings, mark-ups, photographs, sketches,
vendor-supplied product information, etc. with the Deviation Request e-mail. If
attachments exceed mailbox limits then submission should occur via CD-ROM or other
means of sharing large files.
3. Additional information may be requested by the District and/or an alternative solution(s)
presented by the requester. A meeting may be requested by the deviation requester to
explain the issues to the District Project Manager and project team members.
4. NEORSD Staff review of the Standards Deviation Request will result in the District
assigning one of the following statuses:
Accepted – If the requested deviation is acceptable to the District, NEORSD will notify
the requester in writing and will note any limitations placed on the allowable deviation.
Rejected – If the requested deviation is rejected the District will notify the requester in
writing and the work must proceed without delay in accordance with the Contract or other
pertinent procurement requirements.
The District will return a written decision within 10 working days under normal
circumstances. However, complex issues may require additional time for analysis and
preparation of a response. The District will work with the requester if further explanation
or discussion is needed to reach a timely decision.
5. Appeals of the District’s decision shall be submitted within ten (10) calendar days of the
date of the decision and shall be submitted in writing to the District’s Project Manager.
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NEORSD Standards Deviation Request Form
Northeast Ohio Regional Sewer District
3900 Euclid Ave.
Date of Request:
Cleveland, OH 44115 216-881-6600
Project Number:
Name of Requester:
Name of Firm:
Phone No.:
E-mail address:
Attach additional sheets as needed to provide the information required below:
Standards(s) for which a deviation is requested (list document name, section(s), subsection(s):
Fully explain reason for deviation request:
Proposed alternative implementation:
Supporting documentation attached?
Yes
No
Signing below indicates that the Requestor has verified compliance with the requirements of the
Standards Deviation Request procedure included in the NEORSD Automation Standards and Conventions Manual
Requester’s Signature
Date
THIS AREA FOR NEORSD USE ONLY
Date Received:
Date Returned:
Reviewed by:
Authorized NEORSD Signature
District Decision:
Accepted
Rejected
Comments/Limitations:
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Part II Standards and Conventions
SECTION 1 - HMI STANDARDS AND CONVENTIONS
Section 1.0 - Introduction
This section contains standards for process screens as developed for the Northeast Ohio Regional
Sewer District’s Plant Automation System. These screens allow plant operators to monitor and
control field equipment from Area Control Stations (ACSs) located throughout the plant.
Process screens contain several elements that have been standardized during their initial
development. One element is the interface window or template that surrounds process
equipment on each screen. Other elements include symbols that represent field equipment such
as pumps, valves and motors.
Section 1.1 - Process Symbols and Color Conventions
Standards for symbols and colors have been developed to display information on the status of
field equipment and processes. This is to aid operators in interpreting information displayed on
process screens.
Figure II.1.1.1 illustrates the standard colors developed for process piping. Piping is color coded
to indicate material contained within. Process piping is either drawn, using lines with a width of
5 points or 11 points, depending on the relative sizes of lines and what is appropriate to the
layout of equipment on a process screen.
Some pieces of equipment are represented using only static structures. Symbols for these types
of equipment are shown in Figure II.1.1.2.
Elements of these objects do not change as
conditions in the plant, process, or equipment change. They have been included as a point of
reference to operators to help define the location of other pieces of equipment in a process.
The vast majority of equipment, however, is represented on process screens with symbols or
combinations of symbols whose appearance changes as conditions or equipment in the plant or
process change. These symbols are shown in Figure II.1.1.3 through Figure II.1.1.5.
Symbols representing more generic equipment or types of equipment that are more often
encountered are shown in Figure II.1.1.3. Each of these symbols changes color to indicate
equipment status. Red indicates that a piece of equipment is running or a valve or gate is fully
opened. Green indicates that a piece of equipment is off or a valve or gate is fully closed.
Yellow indicates that a piece of equipment is malfunctioning. Black indicates that information is
not available from the HMI process server.
These symbols also allow an operator to send commands to equipment. More will be said on
how commands are sent to equipment in Section II.1.6 – Process Control.
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Figure II.1.1.4 shows other symbols that change as plant or process conditions change. These
symbols contain text describing the state of a piece of equipment. Symbols at the far left side of
the figure are the objects used to build process graphics. These are points appropriate for pumps,
motors, etc.
Figure II.1.1.5 shows a text symbol appropriate for valves and gates. The yellow “Alarm Text
Boxes” are normally not visible on an active screen. However, when an alarm condition arises,
the box becomes visible to notify the operator. The red “Status Text Boxes” appear when an
event or non-alarm process condition occurs.
“Analog Level Indicators” convey analog (continuously variable values) such as speed, level,
flow, etc. The “Analog Set point Box” allows an operator to enter numerical values such as
Setpoints to controllers.
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Section 1.2 - Standard Cimplicity Screen Templates
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Other conventions include:
System Mode – Local mode is black text on green, Remote mode is black text on red.
Bypass Mode – Normal operation (not bypassed) will be black text on green or invisible
altogether, Bypassed will be black text on red.
System Status – Represented with a multistate text box. Normal “ok to start’ is black text on
green; all others (no permissive, standby, etc) are black text on red.
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Section 1.3 - Alarm Priorities
Currently, alarms are prioritized according to the four categories shown below.
Priority 1:
Health and Human Safety Alarms (Chlorine High Level, Explosive Gas
High Level, etc.)
Priority 2:
Conditions that indicate, result in, or may lead to, regulatory permit
violations (e.g. loss of control, loss of signals, chemical addition problems,
water quality sensor alarms, and other alarms associated with regulated
parameters and processes).
Priority 3:
Process variable excursions ("high" and "low" levels), non-catastrophic
machine failures and computer network failures.
Priority 4:
Failover from primary to redundant units (e.g. one of a pair of redundant
processors or communication links failing) or other miscellaneous nonprocess failures.
Priority 4 alarms are only displayed on alarm pages when a person with the privileges of a
system administrator is logged into the system. Operators will only see Priority 1, 2, or 3 alarms.
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Section – 1.4 - Alarm Configuration
Alarms of different priorities are displayed on alarm summary pages using different colors to aid in their
identification. Color coding for alarms is as shown in Table II.1.3.1 below.
Table II.1.3.1 - Alarm Color Configuration
Alarm
Priority
1
2
3
4
Unacknowledged
alarms
Text/
BackForeground
ground
White
Red
Black
Yellow
White
Blue
White
Green
Acknowledged Alarms
Text/
Foreground
Red
Yellow
Blue
Green
Background
White
Black
White
White
Reset Alarms
Text/
Foreground
White
White
White
White
Back-ground
Black
Black
Black
Black
Section 1.5 – Point Tag Naming Convention
1.5.A – Existing Process Loops for Easterly WWTC
1.5.B – Existing Process Loops for Westerly WWTC
1.5.C – Existing Process Loops for Southerly WWTC
1.5.D – Existing Process Loops for Remote Pump Stations
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Section 1.6 - Process Control
In the Automation system, control functions shall be executed exclusively by Programmable
Logic Controller (PLC) units. Logic for safety interlocks, equipment protection interlocks, start
sequences, stop sequences, operational sequences, process and maintenance calculations (e.g.,
flow totalization, equipment run-time accumulators) shall also reside within PLCs. LocalRemote hardware switches on field equipment or panels, and HMI-based Auto-Manual software
switches shall enable control via PLCs. The HMI system shall provide the capability for
operators to start and stop equipment, select equipment for operation, select operating modes
such as lead-lag and other options, change setpoints, manually adjust speed, position,
temperature and other control parameters, and perform other control via interaction with PLCs.
Control commands shall be sent by the HMI subsystem to PLCs which shall respond as
commanded and control equipment. In general, Start-Stop, Open-Close, Auto-Manual, etc.
commands shall be entered in the HMIs via a small popup window that overlays a process
screen. Setpoints shall be modifiable via pop-up windows or via objects placed on process
screens. However, this interaction shall be allowed only when security conditions have been
satisfied. These conditions are based upon the following:
The “Role” of a User
Roles have been defined within the HMI subsystem to differentiate allowable levels of system
access for each type of user. The default level of access, “VIEWER”, has no control of
equipment. Only monitoring of processes and equipment is allowed.
Four other user roles have been defined. Two roles have been defined to differentiate areas of
responsibility of on-site union personnel. These roles are the “2798OPER” operator (for Local
2798 personnel) and the “18OPER” operator (for Local 18 personnel). Users logged in to the
system as a “2798OPER” may not control equipment whose area of responsibility belongs to
Local 18 Union personnel and vice versa.
Two other roles have been created with higher levels of access. The “MANAGER” role for Shift
Managers and Unit Process Managers (UPMs) may control all equipment. The “SYSADMIN”
role for programmer and network administrators may also control all equipment. However, this
is generally for testing and troubleshooting purposes.
Determining the “role” of a user shall be done at the HMI level via login procedures. The HMI
shall prevent the transmission of control commands to PLCs by users attempting to control
equipment inappropriate to their system role.
The Location of a User
Operations personnel at the Southerly Wastewater Treatment Center (SWTC) require operators
to be in the vicinity of the equipment they operate via the HMI. Control functions at the SWTC
shall be enabled at the HMI level based on the node name of the HMI station. Operations
personnel at the nearest node(s) shall be able to control nearby equipment.
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Section 1.7 - Process Control and Automation System Design Support Documentation
It is essential that the District have complete and accurate information describing the sources of
process data monitored by the process control and automation system or by independent data
acquisition systems or components. Designers that are undertaking projects that in any way
involve data acquisition by the District’s instrumentation and/or control systems shall produce,
and incorporate in the design documents, supporting documentation describing in detail any
computations, derivations, extrapolations, and other algorithms, that are used for design of
process data acquisition and control elements. The supporting documentation must include all
relevant details such as equations, constants, variables, exponents, Boolean expressions, timebased actions, scaling factors/conversions, performance computations, look-up tables, and other
mathematical or logic operations. The documentation must provide references for the source of
equations, tables and other algorithms that are used in the design. Examples may be orifice,
weir, sluice, flume, and pipe flow equations, pump curves, venturi curves, and so on.
Generally the process control and automation system design record should include the
determination of proper process variable spans, limits, and custom programmed operations
executed by the process control and automation system involving more than one process
variable. It does not include functions that are already built into the process control and
automation system or those associated with the calculations and operations that are
preconfigured in process instrumentation and electrical equipment such as flow transmitters,
analytical instrumentation, and smart instrumentation/metering. Examples of design record
items may include, but are not limited to:
•
Process variable and equipment parameter spans and limits used in programmed logic
•
Conversion of the measure of tank level into volumetric engineering units based on tank
geometry
•
Estimated time to fill or empty tanks calculated from valve position, pipe size, head,
flow, or other factors
•
Chemical dosage rate based on flow, demand, and chemical strength
•
Wire-to-Water Efficiency for determining selection of best pump combinations.
The design record should identify applicable standards, engineering references, product
documentation, and design factors from all engineering design disciplines that form the basis for
calculations/equations, constants, scaling factors/ranges, and limits, and that validate the
appropriate use/incorporation of these items in process control system programming logic, the
generation of reports, and the collection of historical data. The process control and automation
system design records should summarize design factors and constraints under which their
application in the process control system is subject to. Where specifically cited in the process
control narratives, the design factors shall reference the associated system design record.
Categories into which the design records should be organized are as follows:
•
Process Control and Monitoring
•
Electrical and Mechanical
•
Safety and Security
•
Inventory Management
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•
Regulatory Reports and Requirements
•
Historian.
Within each category, the designer must identify:
•
The design record items by English description and symbolic
(analytical/mathematical/logical) definition,
•
Scientific/engineering and design standards reference source(s) that define or affect the
nature of the item,
•
The process control system database tags and their descriptions associated with the item
as input variables, constants, or results,
•
Assumptions, constraints, and constants that directly influence the item.
Section 1.8 - Custom Programming
Some functions unavailable in the present HMI were created using custom visual basic
programs. In addition, several administrative tools are used which would be considered custom
programming.
Custom programs shall explicitly define each and every variable used within the program. This
definition statement (e.g., “Dim” in Basic, etc.) shall define the data type (e.g., integer, real,
Boolean, string, etc.) and shall contain a comment indicating how this variable is used. Major
blocks of code shall be prefaced with explanatory comments. Comments shall also be included
every two to three lines within blocks to detail the working of specific code sequences.
Current custom programs are related to login procedures, routines related to enable control of
equipment and various system administration tasks.
An operator is required to log in to the system to gain access to control functions (see Section 1.6
for more information). This login is via the operating system’s standard login dialog boxes and
routines. Login routines set drives within the operating system and update local files on the hard
disk drive. Routines also change registry entries and perform file management activities to allow
an operator to resume viewing the same screen he was viewing prior to logging in.
Equipment control is regulated via custom programs that determine the computer from which
control is being attempted and the “role” of the user that has logged in to the system (further
information is contained in Section 1.6). Programs performing these functions are embedded
within each Standard Screen Template (described in Section 1.2), within equipment standard
equipment symbols and within small overlay screens.
A batch command file is used to update screen files on all viewer stations. Timestamps are
compared to avoid unnecessary copying. The operating system’s automated replication
functions are NOT used so that updates are fully completed and deliberately distributed at an
administrator’s discretion.
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Section 1.9 - Reporting Point Changes
When a point is changed, it may impact Operation Data Management System (ODMS) reports,
up to and including EPA 4500 reports. All requests for point changes shall be sent to the District
Manager of Process Control and Automation for approval prior to making the change. The
following is a list of reasons to request a point change:
1. A point needs to be added to the point database and archived to the historian.
2. A point needs to be deleted (that was formerly logged to the historian).
3. A point's derivation needs to change (flows, totalizers, etc). This must be done if the
change will result in the reported value being offset from previous values.
4. Equipment has been changed or replaced (if deleted, see reason 2), if different scaling is
used, new limits or values are required, etc. However, if the new equipment operates the
same as the old equipment, existing points may be used and no notification is required.
5. A derived point needs to be added to the point database. This requires notification unless
the point is used only for convenience on displays, where it is a calculation based upon
otherwise reported points or where the value can be derived in reporting.
6. A general circumstance has arisen that might affect a report.
Items to include in notification:
•
•
•
•
•
•
•
•
•
•
The nature of change(s)
The reason for the request
The date and time field equipment changed or was placed back in service (if
applicable)
Tag ID(s)
Cimplicity Database Logging table name(s) (e.g., S_TC_PRESS)
Oracle field name(s)- usually in the form “[tag_id]_VAL0”; check the appropriate
Oracle table if in doubt
Cimplicity Project for each point (E_PT, E_RS, S_FA, S_LS, S_SA, S_TC, W_WD,
W_WW)
Cimplicity Description(s) / ODMS Label(s)
Point type (Cimplicity) / Parameter type (ODMS) for each point (flow, service,
analytical, etc)
Range and units (if it is an analog value) for each point
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Section – 1.10 - Tag Naming Formats for CLX/WW/PV+
1.10.A – General
This naming convention applies to tags and objects created in Rockwell Logix series of PLC
(CLX). Since CLX uses add on instructions (AOI) to pass data between the Wonderware HMI
(WW) and the PanelView Plus 6 (or current series) OIT (PV+), the CLX tag name must be
identical to the corresponding object name in WW and PV+. Any limitations within those
platforms must also be taken into account.
Internal tag naming (tags not communicated to an outside source) is left to the discretion of the
programmer. However these tags should be clearly understandable and shall have the first letter
of each word capitalized, with no underscores. Example: InternalTagName1.
All tag naming should be consistent. For instance, naming one tag “Input_Pressure1” and
another “Input_PSI1” is an example of two names for the same process parameter. Even if these
tags are not passed to the HMI, this naming convention is unacceptable.
Point tags are not the same as instrument tags. A point tag refers to the parameter associated
with a device; the software tag name. The same loop number shall be used for the instrument tag
and point tag.
The point tag name must appear in the system integrator provided I/O List.
The NEORSD reserves the right to request a different tag name, should any provided tag names
not meet the standard or prove to be unclear.
1.10.B - Format
The approach for tag naming is based upon recognized descriptions for the point tag. All tag
names are limited to a total of 32 characters. All acronyms are upper case letters. No spaces are
allowed in the tag name; underscores are used instead.
The convention takes a hierarchical approach to identifying the point tag.
Site 
Process Area
System 
Train
Equipment
Device
Parameter
Note that not all tags will have every level of the hierarchy.
The CLX/WW Tag format is as follows:
[Site][Area]_[Desc1][Train][Parallel]_[Loop]_[Desc2][Train][Parallel]_[Parameter]
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Where,
Site = Site designation, in upper case. Example sites include:
“S” is used for Southerly Wastewater Treatment Center.
“E” is used for Easterly Wastewater Treatment Plant
“W” for Westerly Wastewater Treatment Center
“C” for Collection System Control Facilities
“Q” for Water Quality Surveillance
Area = the two digit process area number. There is no space between the site and process area
number designators. Refer to Part II Section 9.1 for a complete and up to date listing of process
area numbers.
For systems with remote IO racks, the area number should reflect the location of the IO, not the
PLC.
Desc1 = the first descriptor field, intended for the specific process description. If more
appropriate, it may be used for primary equipment name, area, building, etc.
Train = the process train number; may appear after the first or second descriptions. Use
sequential numbers when more than one train exists.
For examples: INC1 (fluid bed incinerator-train1).
Parallel = the lower case alphabetical designator for multiple equipment operating in parallel on
a single process train. This may appear after the first or second descriptions. For example:
CNT1a (centrifuge ‘a’ for incinerator train 1).
Loop = the loop number from the flow diagram or instrument tag. This is always a 4-digit
number. If the loop number is not available, use “xxxx” as a place holder.
Note that in the case of valves, this will be the valve number and may not match the loop
number.
Desc2 = the second description field intended for the equipment or device associated with the
tag. It may also be used for sub-process areas or components of a larger piece of equipment.
Additional descriptions (_ [Desc3][Train][Parallel) may be added to the tag name as needed.
Parameter = the process variable of the associated equipment. When no parameter is needed,
this field can be used for the object type, such as PID. This is useful in preventing duplicate tag
names.
Not shown in the tag name is the attribute, which is a specific property of an object. The attribute
is NOT part of the tag name; it is defined by the object and not modifiable by the user. These
attributes will link functionality from the CLX to the WW or PV graphics.
Note: The attribute name (and the “.”) do not count in the 32 character limit.
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1.10.C - Object Attributes
To aid in general understanding, a brief explanation of objects and attributes is provided here.
For more information please reference the NEORSD Standard Object Library User Manual.
A complete object consists of three parts: an add-on-instruction (AOI) in the ControlLogix
family of processors, a global object in the OIT (PanelView), and a template instance in
Wonderware. The templates and global objects are designed to align with the AOI, and through
base template scripting (HMI) and RSLinxEnterprise (OIT), automatically link the individual
graphical properties to AOI parameters.
These graphical properties are referred to as attributes. Some typical attributes include
indication, feedback, alarms, and command output.
In the past, each IO point would be mapped to a separate “tag”, resulting in individual tags for
different physical IO, such as “Motor running”, “Motor Speed”, or “Motor Start Command”.
With the District Standard Objects, separate “tags” are no longer to be used. Instead, all of the
parameters of a physical device (limit switches, running feedback, fault indications, etc) are
mapped to a single AOI instance in the PLC. The HMI template instance is linked to this AOI
via scripting and the use of a common object name. To clarify this principle, consider the
implementation of a discrete valve.
Implementation Example
Description: A process water tank1 drain valve 4200 at Southerly Solids Handling Area.
For this example, a discrete control valve will have feedback for open and close, as well as an
output for position control.
Using the tag naming format from above, an acceptable root for a tag name becomes:
S57_PWTNK1_4200_DRV
Using objects, the correct way to implement this valve would be to create an instance of the
Valve_Discrete object, naming it S57_PWTNK1_4200_DRV, and then map each IO point to the
correct parameter of the object AOI:
IO Point
PLC Mapping
HMI Mapping
.
1:4:I.Ch0  S57_PWTNK1_4200_DRV.Inp_OpenLS 
1:4:I.Ch1  S57_PWTNK1_4200_DRV.Inp_CloseLS 
S57_PWTNK1_4200_DRV
1:6:O.Ch8  S57_PWTNK1_4200_DRV.Out

The HMI scripting places each parameter from the PLC into the associated graphical object
attribute.
A common error for programmers new to the idea of objects is to implement the valve using
smaller individual objects, such as a Discrete and Discrete_Indicator. This technique is shown
below as a method of how NOT to implement objects:
Create Discrete_Indicator object S57_PWTNK1_4200_DRV_Opened.
IO Point
PLC Mapping
HMI Mapping
1:4:I.Ch0  S57_PWTNK1_4200_DRV_Opened.ind  S57_PWTNK1_4200_DRV_Opened.ind
Create Discrete_Indicator object S57_PWTNK1_4200_DRV_Closed.
IO Point
PLC Mapping
HMI Mapping
1:4:I.Ch1  S57_PWTNK1_4200_DRV_Closed.ind  S57_PWTNK1_4200_DRV_Closed.ind
Create Discrete object S57_PWTNK1_4200_DRV_CMD.
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IO Point
PLC Mapping
HMI Mapping
1:6:O.Ch8  S57_PWTNK1_4200_DRV_CMD.state  S57_PWTNK1_4200_DRV_CMD.state
1.10.D - Process, Equipment & Parameter Names
Within the tag name format, most fields are intuitive: site, process area, train, and loop should all
be clearly defined. This “fixed” portion of the tag name consumes 11 to 13 characters. The
process and equipment names are equally known, but need to fit within the remaining 19
characters. To aid the programmer in tag name development, the District has compiled a list of
frequently encountered process terms along with the acceptable abbreviation.
For other process and equipment names not listed, it is the programmer’s responsibility to choose
a name that is easily recognized and meets the number of character limitation. Each created
process or equipment name must be consistent through all programming, including HMI, OIT
and multiple PLC programs. For example: if the equipment name for windbox is set as
“windbox” in a PLC tag for incinerator 1, then the PLC for incinerator 2 must also refer to it as
“windbox”; “wind_box would not be acceptable.
The complete list of abbreviations is given in Part IV Section 7 – Process, Equipment, &
Parameter Abbreviations. New abbreviations should be reviewed by the District or its
representative prior to implementing in a tag name.
1.10.E - Example Tag Names
The following examples are provided to assist in illustrating the tag naming format.
S47_INC1_xxxx_WB_PSI
where “S” represents the Southerly site.
"47" is the process area number for incineration.
"INC1" is the fluidized bed incinerator, process train 1.
“WB” is windbox, the device or equipment description.
"PSI" is pressure, the process parameter.
CNM_BS1_Inlet_LVL
where “C” represents a collection site (Remote Pump Station in this case).
“NM” is for “Nine Mile”.
“BS1” is for bar screen 1.
“Inlet_LVL” is level on the inlet side.
Since a Remote Pump Station and similar sites do not need numerical “process area numbers”,
the two character alpha abbreviation (nm, for example) will serve as the location in the
ProcessAreaNumber/Location part of the tag.
Other sample ControlLogix and Wonderware tags:
S47_INC1_xxxx_PHB1_NG_FLW (pre-heat burner 1 natural gas flow)
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S57_CNT1A_xxxx_ScrollDrive_SPD (centrifuge ‘a’ on train 1, scroll drive speed)
S57_POL_xxxx_STNK1_LVL (polymer storage tank 1 level)
S57_PHU1A_xxxx_PLP_PipeA_PSI (pump hydraulic unit, train 1, unit “a”, pipeline lubrication
pump pipe “a”, pressure)
S57_SH_xxxx_SK_TMP1_HH (solids handling, skimmings temperature 1, HIHI)
S57_SH_xxxx_SK_TMP1_HH_STPT (solids handling, skimmings temperature 1, HIHI alarm
setpoint)
When an average is created from several redundant measurements, use the following example as
a guide:
S47_INC_3100A_HX_IN_GAS_TMP (heat exchanger inlet gas temperature A)
S47_INC_3100B_HX_IN_GAS_TMP (heat exchanger inlet gas temperature B)
S47_INC_3100C_HX_IN_GAS_TMP (heat exchanger inlet gas temperature C)
S47_INC_3100AVG_HX_IN_GAS_TMP (heat exchanger inlet gas temperature average)
1.10.F - Format for Description Field
The point tag description, in CLX, WW, and PV+, shall consist of the P&ID tag name (in upper
case letters), followed by a full description of the tag.
1.10.G - Other Requirements
All IO list must include the point tag and corresponding object_name.attribute information, as
well as any alarm descriptions. Alarm descriptions must be consistent between HMI and OIT.
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SECTION – 2 - PLC PANEL CONSTRUCTION STANDARDS
Section 2.0 - Introduction
This section reviews the conventions for PLC panel construction.
Section 2.1 - Panel Construction
Article I provides the detailed requirements for the construction of control and PLC panels.
Included in this article are the requirements for the following:
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
Documentation
General Panel Requirements
Panel Construction Requirements
Environmental Control
Electrical Requirements
Identification
Warranty
Inspection and Testing
Factory Acceptance Test
Site Acceptance Test
Article II provides reference standards and Article III contains installation details.
CONTRACTOR shall provide all labor, materials, equipment, and incidentals required to
furnish, install, calibrate, test, start-up, and place into satisfactory operation all control panels
and/or enclosures. No omission in these or related specifications and/or drawings shall relieve
the CONTRACTOR of supplying complete, functional, and operational panels or equipment.
Related References: NEORSD Electrical Standards and Conventions Manual
Detailed Specifications
A. Documentation
1. Layout drawings, wiring schematics, and parts lists are to be supplied in hard and
electronic copy for approval before building commences. On successful
completion of site acceptance test, the CONTRACTOR shall provide all “AsBuilt” documentation and drawings in hard and electronic copy. All final and
field mark-ups shall be incorporated electronically. Hand-written revisions are
not acceptable. Final documentation must include the following:
a. Wiring diagrams including all wire and terminal numbers
b. Wiring schedules and interconnection diagrams
c. Panel layouts
d. Parts list or bill of materials showing tag number or identifier, quantity,
make, model number, and description for panel and all components and
devices.
e. Installation drawings
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f. Installation, operation & maintenance manuals
g. All information, including panel weight, power supply requirements, etc.
necessary for installation of the control panel(s)
h. Test and completion certificates
i. Operating characteristics of fuses and circuit breakers (manufacturer’s
technical data sheets)
j. Size and weight of all shipping containers.
2. Provide a list of recommended spare parts.
B. General Panel Requirements:
1. Provide all electrical components and devices, support hardware, fasteners, and
interconnecting wiring to make the control panels complete and operational.
2. Locate and install all devices and components so that connections can be easily
made and so that there is ample room for servicing or replacing each item.
3. Unless otherwise specified, cable and conduit entry will be from the top of panels.
4. Adequately support and restrain all devices and components mounted on or
within the panel to prevent any movement.
5. Provide sub-panels for installation of all relays and other internally mounted
components.
6. The panel shall be sized for 25 percent additional space requirements beyond
present needs for future use. Both the front of the panel where devices are
mounted and the interior of the panel shall be sized for 25 percent spare space.
Nothing shall be mounted in space reserved for future use.
7. All I/O spares shall be fully pre-wired from the I/O terminations to the panel side
of interposing terminals. (The other side of the interposing terminals is reserved
for field terminations).
8. Panel shall be equipped with door(s) for front of panel opening.
9. All vendor-supplied or sub-contractor supplied panels shall also conform to the
requirements of this and related specifications.
10. CONTRACTOR shall be responsible for the detailed layout and design of the
panels in accordance with standard practice and techniques and local and national
codes and requirements. The actual layout shall be subject to approval by
ENGINEER.
11. Panel shall be UL approved and meet applicable UL standards including, but not
limited to, UL 508 [Standard for Industrial Control Equipment] , UL508A
[Standard for Industrial Control Panels], UL 698 [Standard for Industrial Control
Equipment for Hazardous (Classified) Locations], UL 698A (Standard for
Industrial Control Panels Relating to Hazardous (Classified) Locations].
12. Panel shall meet applicable sections of the latest edition of the NEC including, but
not limited to, Article 409 [Industrial Control Panels]. Provide calculation and/or
method for determining short-circuit current rating.
13. All panels, materials and equipment shall be new and shall be built in an
Underwriters Laboratory (UL) approved panel shop and bear the UL label.
C. Panel Construction Requirements
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1. Panels located in control rooms and other environmentally-controlled rooms shall
be steel with a NEMA 12 rating.
a. Exterior surfaces to be primed and painted with three coats enamel or
better. Color to be ANSI 61, light gray or as specified.
b. Interior and mounting panels to be primed and painted with two coats of
white enamel or better.
c. Provide one quart of touch-up paint for each color
d. Mounting panels to be 12 gauge steel.
2. Panels located in all other locations shall be Type 316L unpainted stainless steel
with a smooth brushed finish and a NEMA 4X rating.
a. Mounting panels to be stainless steel.
b. Seamless foam-in-place door gasket.
c. All panel penetrations shall be sealed watertight and maintain the NEMA
4X panel rating.
d. Any panel or door mounted devices (e.g., pushbutton) or instruments
shall have a NEMA 4X rating. Whenever an instrument is not available
with a NEMA 4X rating it shall be mounted with a clear plastic,
gasketed, lockable hinged door.
3. Floor-mount panels shall be minimum 12-gauge for all surfaces.
a. Seams continuously welded and ground smooth
b. Remove corrosion, burrs, sharp edges, and mill scale
c. No holes or knockouts unless otherwise specified
d. Removable heavy gauge continuous stainless steel door hinges.
e. Provide 12-inch floor stands welded to the enclosure unless otherwise
specified. Floor stands to be stainless steel for NEMA 4X panels.
f. Rolled flanges around three sides of door and all sides of enclosure
opening to exclude liquids and contaminants
g. Overlapping doors or removable center post.
h. Body stiffeners and panel supports as required
i. Provide handle-operated, oil-tight, key-lockable three point stainless steel
latching system with rollers on latch rods for easy door closing for
control room panels.
j. Data pocket mounted inside panel on door(s)
k. Oil-resistant door gasket with oil-resistant adhesive
l. Ground studs in body of enclosure
m. Bonding provision on doors
n. Lifting eyes, as required. NEMA 4X panels to have stainless steel lifting
eyes.
o. Bottom 12 inches of panels shall be free of all devices, including terminal
strips, to provide ease of installation and testing
p. No device mounted on a surface or door of the panel shall be mounted
less than 36 inches above the operating floor level unless otherwise
specified.
4. Frame or wall-mounted panels shall be minimum 14-gauge for all surfaces.
a. Seams continuously welded and ground smooth
b. No holes or knockouts unless otherwise specified
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c. Removable heavy gauge continuous stainless steel door hinges.
d. External wall-mounting brackets
e. Rolled flanges around three sides of door and all sides of enclosure
opening to exclude liquids and contaminants
f. Stainless steel quick release screws and clamps on three sides of each door
g. Hasp and staple for padlocking
h. Data pocket mounted inside panel on door(s)
i. Oil-resistant door gasket with oil-resistant adhesive
j. Ground studs in body of enclosure
k. Bonding provision on doors
5. Panels Located in Hazardous (Classified) Locations
a. In addition to meeting the applicable requirements of this specification:
1) Indoor panels to be installed in NEC Class 1, Division 1 or 2 areas
(gas/vapor locations) shall meet NEMA 7 requirements.
2) Indoor panels to be installed in NEC Class 2, Division 1 or 2 areas
(dust locations) shall meet NEMA 9 requirements.
b. Required Features:
1) Light weight and corrosion resistant copper-free aluminum
2) Integral, cast-on mounting lugs
3) Viewing windows, if required, sized to suit internally-mounted
components
4) Stainless steel cover bolts
5) Cadmium-plated steel mounting pans
6) Manufacturer: Adalet or equal
c. CONTRACTOR may meet hazardous area requirements through alternate
means such as purging or the use of intrinsic safety barriers only after
consultation with ENGINEER and with ENGINEER’s expressed, written
consent.
D. Environmental Control
1. Provide 120 VAC strip heaters inside panels, as required, to maintain panel
temperature 10°F above ambient to prevent condensation within panel.
2. Provide automatically-controlled closed-loop ventilation fans or closed- loop air
conditioners with filtered air louvers, if required, to maintain temperature inside
each enclosure below the maximum operating temperature rating of the
components inside.
3. Air conditioner shall have a minimum capacity of 4,000 BTU.
4. Provide thermostatic control for automatic changeover from heating to cooling
without the need for manual intervention.
5. Alternative cooling methods such as vortex coolers, thermoelectric
heater/coolers or heat exchangers are acceptable but need approval of
ENGINEER. Contractor shall supply District-approved air compressors if
vortex coolers are approved by the District.
6. Provide heat calculations for each panel or enclosure to verify that there is
sufficient dissipation of generated heat to maintain interior panel temperature
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and humidity within the maximum and minimum operating parameters of all
panel components.
E. Electrical Requirements
1. Power Source and Internal Power Distribution
a. Panel power supply voltage, breaker size (in amps), power panel
identification, and circuit number shall be shown on the Drawings.
b. The panels shall be provided with an internal 120 VAC power distribution
with separate circuit breakers, sized as required, to distribute power.
Provide circuit breakers for 24 VDC instruments with no more than six
devices on a single circuit. Provide 20% spare (minimum of two) installed
breakers or fused terminations for each type and voltage level.
c. All 120 VAC instrument power circuits shall be protected by separate DIN
rail mounted circuit breakers by Idec or equal.
d. When DC power and/or low voltage AC power is required, provide,
install, and wire the necessary power supplies and transformers in the
panel. For example, all panels shall have a 24 VDC power supply wired
to power analog signals that are not otherwise powered.
2. Convenience Accessories
a. One 120 VAC, 20 A, duplex, grounding type receptacle.
b. 120 VAC fluorescent light fixture(s) with shielding and filtering to
minimize EMI. Lamp wattage (minimum 20 W) and number of fixtures
suitable for sufficient illumination of entire panel.
c. One 120 VAC, 20A snap switch for light fixture(s), mounted in a metal
outlet box with a metal cover. Locate in an area easily accessible from
access door.
d. The light fixture(s) and duplex receptacle shall have its own circuit
breaker wired to separate terminals for separate 120 VAC service.
3. Wiring and Termination
a. All wiring to panel connections from field instruments, devices, and other
panels shall be terminated at master- numbered terminal strips, unless
otherwise specified.
b. Splicing of conductors or cables is not permitted.
c. Provide copper grounding studs for all panel equipment.
d. Internal wiring shall be Type THHN stranded copper wire with
thermoplastic insulation rated for 600 V at 85 C for single conductors,
color coded and labeled with wire identification.
e. For internal panel DC signal wiring, use shielded, minimum No. 18 AWG.
For DC field signal wiring, terminal strips shall be capable of handling
minimum No. 12 AWG wiring.
f. For internal panel AC power wiring, use minimum No. 12 AWG. For AC
signal and control wiring, use minimum No. 16 AWG. For wiring
carrying more than 15 amps, use sizes required by the NEC.
g. Separate and shield DC signal wiring from power and control wiring by a
minimum of 6 inches. Design to avoid DC and power/control wiring from
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crossing each other. If a crossing cannot be avoided, then the crossing
shall be at right angles.
h. Group or bundle parallel runs of wire using covered, slotted troughs.
Maximum bundle size to be 1 inch. Troughs shall have 50 percent spare
design capacity.
i. Install wire troughs along horizontal or vertical routes to present a neat
appearance. Angled runs are not acceptable.
j. Mount wire troughs parallel to terminal strips. Provide adequate spacing,
with a 4" minimum, in order to read wire identification tag without
opening wire trough or moving any wires or panel components.
k. Adequately support and restrain all wiring runs to prevent sagging or other
movement.
l. Terminate all field wiring on minimum 600 V rated terminal blocks.
Fused terminal blocks shall have a minimum 300 V rating and shall have
blown fuse indication. All terminal blocks shall be mounted on rigid, high
rise aluminum DIN rail. Use Allen-Bradley Cat. No. 1492-DR6 or
approved equal. Terminal blocks shall be IP2X finger safe and UL rated.
No 120 VAC (or higher voltage) exposed terminals allowed. Terminal
blocks shall accommodate minimum 12 AWG wire. Terminals to have
screwed connections and numeric identifiers beside each connection.
Identifiers to be plastic inserts or self-stick plastic tape with permanent,
machine-printed numbers. Provide Allen-Bradley 1492 series, Phoenix
Contact or approved equal.
m. All wiring shall be installed such that if wires are removed from any one
device, power will not be disrupted to any other device.
n. All spare I/O points shall be wired completely to all termination points
including PLC I/O terminations and interposing terminal blocks.
o. Provide spare terminal blocks equal in number to 20 percent of the
terminals used for each type of wiring (i.e., DC signal, AC power, shields,
and grounds) and for each type of terminal block with a minimum quantity
of five for each type of block and type of wiring. Provide a separate
terminal for grounding each shielded cable.
p. Use separate 5/16-inch diameter copper grounding studs for instrument
signal cable shields and AC power.
q. Where wires pass through panel walls, provide suitable bushings to
prevent cutting or abrading of insulation. Penetrations to be sealed
according to panel NEMA rating and environmental requirements.
r. Provide complete wiring diagram showing "as built" circuitry. All
revisions must be done in CAD—no hand-written revisions allowed.
Diagram shall be enclosed in transparent plastic and placed in easily
accessible pocket built into panel door.
s. Comply with applicable requirements of Section 2.3 – Panel Wiring and
Part II, Section 7 – Electrical Standards
4. EMI / RFI Protection
a. Construction and design techniques shall be used to minimize EMI / RFI.
Use shielding, physical separation, filters, ferrite beads, or other methods
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to insure no interference to or from electrical or battery-operated
components or devices.
5. Surge Protection
a. General: Surge protection shall be provided to protect the electronic
instrumentation system from surges propagating along the signal and
power supply lines. The protection systems shall be such that the
protection level shall not interfere with normal operation, but shall be
lower than the instrument surge withstand level, and be maintenance free
and self-restoring. Instruments shall be housed in suitable metallic cases,
properly grounded. Ground wires for all surge protectors shall be connected to a good earth ground and where practical each ground wire run individually and insulated from each other. These protectors shall be mounted
within the instrument enclosure or a separate junction box (compatible
with the area designation) coupled to the enclosure.
b. Provide formal lightning and surge protection devices for all signal lines,
data highways, and power interfaces with PLCs at remote sites. For signal
lines, data highways, and power feeds to control panels and PLC
hardware, provide formal lightning and surge protection devices for all
lines that originate or are routed outside a building on any part of the
existing or proposed circuit, either in buried or exposed raceways.
c. Lightning and surge protection devices shall be standard manufactured
products comprising multi-component networks or hybrid circuits. The
units shall incorporate gas filled discharge tubes, metal oxide varistors,
and/or zener diodes providing full protection from line to line and from
line to ground. Units shall be DIN-rail mounted, rated for a minimum
10kA maximum surge current and voltage suitable for the type of circuit
being protected. Reaction time shall be on the order of nanoseconds.
d. For signal lines use the SD series, as manufactured by MTL, or approved
equal.
e. For data highways use MTL ZoneBarrier or IP series data communications
protectors; or the Suppressor, as manufactured by ITD, or approved equal.
f. For fieldbuses use FP or TP series from MTL, or approved equal.
g. For AC power lines use MA series from MTL, or approved equal.
F. Identification
1. Provide laminated plastic nameplates for identification of panels and its
components. Nameplates shall be 3/32-inch thick laminated phenolic type with
white matte finish and black letter engraving. Nameplates shall be attached to
the panel face with two stainless steel self-tapping screws.
a. Panel identification nameplates to have 1/2-inch high letter engravings.
b. Panel-mounted component (i.e., control devices, indicating lights, selector
switches, instruments, etc.) identification nameplates to have ¼-inch high
letter engravings. Include legend plates for items like push buttons, pilot
lights and selector switches to show indication or position function (e.g.,
ON or HAND-OFF-AUTO).
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c. Nameplate engravings shall include the instrument or equipment tag
number and descriptive title as shown and specified.
2. Tag all internally-mounted instruments in accordance with the following
requirements:
a. Tag numbers shall be as listed in the Instrument Index, data sheets,
drawings, or specifications.
b. The identifying tag number shall be permanently etched or embossed onto
a stainless steel tag securely fastened to the device housing with stainless
steel rivets or self-tapping screws of appropriate size.
c. Where neither of the above fastenings can be accomplished, tags shall be
permanently attached to the device by a circlet of 1/16-inch diameter
stainless steel wire rope.
d. Identification tags shall be installed so that numbers are easily visible to
service personnel.
e. Front of panel mounted instruments shall have the tag attached to rear of
device (in addition to the front of panel nameplate).
3. Label internally mounted components and devices (e.g., power supplies, power
distribution blocks), mounting rails (e.g., for terminal blocks), etc. with phenolic
nameplates attached with self-tapping stainless steel screws or adhesive or with
other approved method. Attach to mounting plate or panel surface near the
device in a manner that makes identification unambiguous. Manufacturerprovided identification means are acceptable if approved by the ENGINEER.
4. Tagging of the following items shall be accomplished with the use of machinegenerated adhesive plastic labels by Brady or equal.
a. Tag all electrical devices (circuit breakers, relays, timers, etc) mounted
within control panels and enclosures. Do not cover model numbers or
other text or indicating lights.
b. Numerically tag individual terminals or terminal blocks (pre-printed pushon plastic labels from vendor may be used).
c. Color code and numerically tag wiring at each end according to drawings
or other documents, as applicable.
d. Tag all pneumatic lines.
G. Warranty
1. The CONTRACTOR is responsible at their expense for the replacement of any
defective component(s) or the repair of failed systems which arise for a
minimum of twelve months after shipment to the OWNER. Repaired or
replaced components shall be warranted for a period of not less than six months
from date of shipment to the OWNER or the remainder of the original warranty
term, whichever is longer.
H. Inspection and Testing
1. All panels, consoles, and cabinets shall be inspected by the CONTRACTOR.
Inspection shall include, but not be limited to, the following:
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2.
3.
4.
5.
a. Nameplates, warning labels, and tags including correct spelling, color and
size of labeling and characters
b. Enclosure flatness, finish, and color
c. Proper operation of doors, catches, and locks
d. Wire types, sizes, and colors
e. Proper wiring layout, practices and grounding
f. All electrical circuits checked for continuity
g. Terminal block contact ratings and numbers
h. Terminal block, fuse, breaker, & other required installed spares
i. General arrangement and space allocation
j. AC/DC power checks
k. Power fail/restart tests
l. Diagnostic checks
m. All electrical circuits energized simultaneously and continuously for 48
hours without failures
n. All alarm circuits connected to simulated alarm contacts to verify
operation
o. All interlock and shutdown circuits checked for operability and proper
function by means of simulated contact
p. All input/output devices and components shall be tested to verify
operability and basic calibration.
q. Simulate operation of electronic control and receiving instruments and
circuits
r. Test demonstrating that all specified equipment functional capabilities are
working properly.
s. Verify that communication between units is working properly
t. Any other test required to place the panel in an operating state
u. Compliance with specifications, standards, and codes
The ENGINEER reserves the right to inspect the work-in-progress at any time
during the construction or testing of the panels. CONTRACTOR shall notify
ENGINEER when:
a. Panels are furnished with components and wiring is 25% complete.
b. Panels are complete and CONTRACTOR tested.
The ENGINEER shall have the right to request any additional tests that are
deemed necessary to prove the operation of the panel(s) or adherence to the
specification, standards, or codes.
Witnessing by the ENGINEER of any tests and inspections at the
CONTRACTOR’s premises (or elsewhere) shall not imply acceptance of
responsibility for any faults or failings subsequently found.
All problems or discrepancies must be corrected and required retesting
completed before final approval for shipment is given by the ENGINEER.
I. Factory Acceptance Test
1. In the case of panels which form part of an overall control or operating system or
at the ENGINEER’s discretion, testing at the CONTRACTOR’s facility will be
required.
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2. The CONTRACTOR shall be required to write test plans, if required, and
perform the testing. If required, CONTRACTOR shall also perform and
document testing prescribed by ENGINEER and to document testing on
ENGINEER-provided forms. Testing to be witnessed by the ENGINEER.
3. Copies of all test plans and results, certificates, etc. shall be provided to the
ENGINEER.
4. It shall be the responsibility of the CONTRACTOR to furnish all necessary
testing devices which must have a current, valid certificate of calibration.
Calibration records must be produced to the ENGINEER on request.
J. Site Acceptance Test
1. If part of the contract requirements, the CONTRACTOR shall be required to be
on-site with the appropriate hardware and personnel for unpacking and
installation of the control panels.
2. Comply with contract requirements for testing and/or Section 01660, Field Tests
of Equipment.
Reference Standards
• American Society for Testing and Materials (ASTM).
• National Fire Protection Association (NFPA) and the National Electrical Code (NEC).
• National Electrical Manufacturers Association (NEMA) Standards.
• National Institute of Standards and Technology (NIST)
• American National Standards Institute (ANSI).
• Underwriters Laboratories, Inc (UL)
• Factory Mutual (FM)
• The International Society of Automation (ISA)
• Occupational Safety and Health Administration (OSHA) Regulations.
• Federal, state, and local code requirements.
• Where any conflict arises between codes or standards, the more stringent requirement shall
apply.
Installation Details - this section does not contain all installation details for the equipment/
system shown, only those that are required by the NEORSD. These details may exceed those
required by the equipment manufacturer or local codes.
1. Install equipment in conformance with NEC.
2. Unless otherwise noted, install indoor, freestanding and floor-mounted panels on 4-inch
grout pad. Lay grout after panel sills have been securely fastened down. Extend pad 4
inches beyond outside dimensions of base, all sides, solid, face-to-face.
3. Unless otherwise noted, install outdoor free-standing and floor-mounted panels on a
reinforced concrete pedestal:
4. Minimum Thickness: 8 inches with No. 4 steel reinforcing bars at 12 inches on centers, each
way.
5. Minimum Size: 12 inches larger than outer dimensions of base, each side.
6. Provide excavation and backfill work in conformance with the Division 2 specifications.
7. Provide concrete work in conformance with the Division 3 specifications.
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8. Unless otherwise noted, install all frame-mounted indoor and outdoor panels using 316
stainless steel strut style structural support framing system members, plates, and fasteners.
Frame bases shall be installed on a minimum one-inch thick non-shrink grout pad with edges
sloped away from the base plate.
9. Install wall mounted enclosures and control panels using appropriately sized aluminum or
316 stainless steel strut style support channels securely anchored to wall surface to provide
offset mounting for air circulation behind panel. Do not install wall-mounted panels directly
on wall surfaces. Comply with requirements of the Division 26 specifications for support
framing system materials and methods. (Reference Part II, Section 7.1)
10. Install anchor bolts and anchor in accordance with the Division 5 specifications.
11. Install and interconnect all equipment, devices, electrical hardware, instrumentation, controls,
and process control components into and out of and among the enclosures.
Section 2.2 – PLC Hardware & Software
2.2.A – Allen_Bradley PLC-5 (no longer specified for new construction)
2.2.B – Rockwell SLC-500 Series (no longer specified for new construction)
2.2.C - Rockwell ControlLogix
Detailed Specifications
A. PLC Processors:
1. Program Memory Size: 4M Bytes minimum.
2. Memory Type: Program and data in non-volatile RAM, backed up with an
energy storage module. Operating system in non-volatile firmware.
3. I/O Capacity: 128,000 discrete I/O (any mix of inputs and outputs) or 4000
analog I/O, maximum.
4. Up to 500 connections (nodes). Up to 64 connections over ControlNet
(maximum of 48 recommended). Up to 128 connections over Ethernet / IP.
5. Bit execution time less than 0.15 microseconds.
6. Installation Location: Left-most slot of the I/O chassis (typical).
7. Diagnostics:
a. Standard, self-diagnostic routines shall be provided to determine proper
hardware and software operation.
b. Diagnostic LEDs shall be provided on the processor front panel to indicate
the following:
1) Processor running.
2) Processor fault.
3) Battery low.
4) Forced I/O.
5) Communications active.
6) Communications error.
8. Communications: The PLC processor shall be equipped with on-board
communications ports for the following:
a. USB port.
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9. Instruction Set:
a. The PLC shall be equipped with the following instructions as a minimum:
1) Relay-type logic functions including normally open contacts,
normally closed contacts, and output coils.
2) Timers: On delay, off delay, and retentive.
3) Counters: Up, down.
4) Math functions including integer and floating point, add, subtract,
multiply, divide, and square root.
5) Data transfer instructions.
6) Logical AND, NOT, OR, XOR instructions.
7) Compare Instructions: Equal to, greater than, less than.
8) Proportional - Integral - Derivative control instruction.
b. The PLC shall support branching functions to allow any combination of
series or parallel instructions.
c. The PLC shall support the use of subroutines where appropriate.
10. Programming software: Rockwell RSLogix 5000. IEC 61131-6 compliant.
Available languages:
a. Ladder logic
b. Function block diagram (FBD)
c. Sequential function charts (SFC)
d. Structured text
11. Online programming including run-time editing
12. Manufacturer and Model:
a. Allen-Bradley Cat # 1756-L7X-K, where X is the numeral 2 or higher
current model.
b. Order with conformal coating (“K” designation) when available.
B.
Network Communications:
In addition to the communication ports available on the processor, select
communication modules for the following networks, as required:
1. Ethernets / IP (Cat# 1756-ENBT or 1756-EWEB [for web-enabled Ethernet] or
1756-EN2T [for redundant rack communication]
2. ControlNet (Cat# 1756-CNBK)
3. DeviceNet (Cat# 1756-DNBK)
4. Data Highway Plus (DH+) (Cat# 1756-DHRIOK)
5. Universal Remote I/O. (Cat# 1756-DHRIOK)
6. Foundation Fieldbus (Cat# 1788-CN2FF or Cat# 1757-FFLDK)
7. HART (latest version of ProSoft HART Multi-drop Master Communications
Module, Cat# MVI56-HART, etc.)
8. Modbus (latest version of ProSoft Modbus Master/Slave Enhanced
Communications Module, Cat# MVI56E-MCM)
9. Serial Network (Built-in serial port on processor or Cat# 1756-MVI, -MVID)
10. DH-485 (Built-in serial port on processor)
11. Order with conformal coating (“K” designation) when available.
C.
Power Supplies:
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1. Chassis Power: Each PLC processor and remote I/O chassis shall include a power
supply. The power supply shall be sized, at a minimum, to accommodate all
spare and future I/O. The power supply shall be mounted on the left end of the
I/O chassis and plug directly into the backplane. If the addition of I/O to an
existing chassis requires a larger power supply, then that power supply shall be
supplied by the contractor or responsible entity.
2. Input Voltage: 120 VAC, 60 Hz.
3. Output Current: 13 A at 5 VDC, minimum.
4. Provide all cabling as required.
5. Manufacturer and Model:
a. Allen-Bradley 1756-PA75/BK
b. Order with conformal coating (“K” designation) when available.
6. Field Devices: Provide power supply to power field devices that require 24 VDC.
Mount alongside I/O chassis.
7. Input Voltage: 120 VAC, 60 Hz
8. Output Current: Sized for loads at 24 VDC, with 25% spare capacity.
9. Provide all cabling as required.
10. Manufacturer and Model:
a. Allen-Bradley 1606-XLS Performance Series
11. Provide DeviceNet or other fieldbus power supplies and power conditioners, as
required.
D.
I/O Chassis:
1. Type: I/O chassis designed to house the PLC processor, network communication
interface modules (including Ethernet, ControlNet, DeviceNet, and universal
remote I/O communication modules, etc.), and the I/O modules. The chassis
shall be sub-panel mounted.
2. Provide all required signal and power cables between I/O chassis and power
supplies, as required.
3. Manufacturer and Model:
a. Allen-Bradley 1756-A4K (4 slot), 1756-A7K (7 slot), 1756-A10K (10
slot), or 1756-A13K (13 slot), 1756-A17K (17 slot). All are back-panel
mount type.
b. Order with conformal coating (“K” designation) when available.
4. Available with Class 1, Division 2 hazardous area certification.
E.
I/O Modules:
1. Available Types: The types of I/O modules available for use with the PLC
system shall be as required. Provide screw-clamp or spring-clamp extended
depth removable terminal blocks for all I/O cards (depending on configuration of
interposing terminations). Wire size range from #22 AWG to #12 AWG. The
following types of manufacturer standard I/O modules shall be available:
a. Sixteen point individually isolated discrete input modules which accept an
input of 120 VAC, 60 Hz. (Cat# 1756-IA16IK)
b. Sixteen point individually isolated discrete input modules which accept an
input of 24 VDC, sink or source. (Cat# 1756-IB16IK)
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c. Sixteen point isolated output modules. Each output point shall be
independently fused and individual blown-fuse indication for each point.
Isolated outputs shall have a current capacity of 2 amps at 120 VAC.
(Cat# 1756-OW16IK)
d. Sixteen point isolated discrete output modules @ 24 VDC, sink or source
with each output fused with individual blown-fuse indication. (Cat# 1756OB16IK)
e. Eight point isolated relay output modules with an output current capability
of 2A at 120 VAC per point. (Cat# 1756-OX8IK)
f. Eight point isolated analog input modules (16 bit minimum resolution)
which accept an input of 4-20 mA DC and read the HART signal. (Cat#
1756-IF8HK)
g. Six isolated thermocouple inputs. (Cat# 1756-IT6IK) (However, use
transmitters and 4-20mA inputs whenever possible.)
h. Six isolated RTD inputs. (Cat# 1756-IR6IK) (However, use transmitters
and 4-20mA inputs whenever possible.)
i. Eight point isolated analog output modules (15 bit minimum resolution)
which produce an output of 4-20 mA DC and read the HART signal.
Analog output modules shall allow selectable output response to faults of
minimum, maximum, or last output value. (Cat# 1756-OF8HK)
j. Slot fillers for unused I/O slots. (Cat# 1756-N2)
k. Order with conformal coating (“K” designation) when available.
2. Required Features: The I/O modules and system hardware supplied shall
incorporate the following design and construction features and comply with the
following requirements:
a. All I/O modules shall be supplied with Allen-Bradley extended depth
removable terminal blocks that plug into the front of the I/O module.
b. Noise immunity and filtering.
c. IEEE surge-withstand rating to IEEE 472.
d. Optical isolation for all inputs and outputs to provide controller logic
protection.
e. Any card, any slot, plug-in packaging. Mechanical keying of I/O module
to its removable terminal block (RTB) to ensure module is placed in
correct slot after removal. Electronic keying between I/O module and
processor ensures correct module type and revision. All modules shall be
replaceable under power.
f. Software configuration of modules (no jumpers or switches).
g. 300 volt I/O wiring terminal arms sized to accommodate up to #14 AWG
wires. Wiring design shall allow I/O module removal and replacement
without disturbing I/O wiring connections.
h. Front-of-module LED Status indicators for each individual input and
output point are to indicate when power is applied at I/O terminals.
i. Fused output circuits for all output modules with blown fuse indication.
j. Where required and recommended by the manufacturer, external transient
suppressor shall be provided for installation across the output loads.
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3.
4.
5.
6.
F.
k. Scaling to engineering units for analog modules.
l. Provide required connectors with each I/O module.
Provide minimum 20% spare installed I/O for each type of I/O installed in every
chassis.
Provide minimum 25% spare space in every chassis for future expansion.
All I/O, including spares, shall be wired to terminal blocks prior to
interconnection with other devices. See Part II, Section 5.1 – Panel Construction;
Paragraph E.3, for terminal requirements.
Manufacturer:
a. Allen-Bradley - Model according to I/O Schedule.
Software:
1. Provide a licensed copy of all programming and configuration software to the
District, including electronic and hard copies of all manuals. The following
software packages shall be furnished in addition to all other software necessary
for the proper programming and configuration of the PLCs and their components:
a. RS Logix 5000
b. RS NetWorx for ControlNet
c. RS NetWorx for DeviceNet
d. RS Linx
e. FactoryTalk View ME
Section 2.2.D - Rockwell CompactLogix
Detailed Specifications
A. PLC Processors:
1. The processor shall have a memory expansion submodule with a minimum of 2
megabytes of user memory.
2. I/O Capacity: Total I/O maximum of 480 (any mix).
3. Module Expansion: Minimum of 2 banks.
4. Program Scan Time: 0.08 ms (Boolean).
5. Installation: Left most module on PLC DIN rail.
6. Communication Ports: One (1) USB port and two (2) Ethernet ports.
7. Manufacturer and Model: Allen-Bradley CompactLogix 1769-L33ER-K, or
current model.
a. Order with conformal coating (“K” designation) when available.
8. Programming Software: Rockwell RSLogix 5000. IEC 61131-6 compliant.
B.
Network Communications:
1. Ethernet I/P – use port on processor. If additional Ethernet ports are required
then use model 1768-ENBTK.
2. ControlNet: Cat# 1769-CNBK
3. DeviceNet: Cat# 1769-SDNK
4. Other networks, as required.
5. Order with conformal coating (“K” designation) when available.
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C.
Power Supplies:
1. Input Voltage: 120 VAC, 60 Hz
2. Output Current: 4A at 5 VDC, minimum
3. Provide cabling, as required.
4. Manufacturer and Model: Allen-Bradley Cat# 1769-PA4K.
a. Order with conformal coating when available
5. Field Devices: Provide power supplies to power field devices that require 24
VDC. Mount next to modules.
a. Input Voltage: 120 VAC, 60 Hz
b. Output Current: Sized for loads at 24 VDC with 25% spare capacity.
c. Provide cables and fusing
d. Manufacturer and Model:
1) Allen-Bradley 1606-XLS Performance Series
6. Power DeviceNet or other fieldbus power supplies and power conditioners, as
required.
D.
I/O Modules:
1. Analog Input:
a. Inputs: 4 differential or single-ended 4-20 mA (isolated) with HART
communications
b. Resolution: 16-bit (unipolar)
c. Installation: PLC DIN rail. Provide all DIN rail and mounting hardware.
d. Connection Adapter, Cable, and Terminal Block:
e. Manufacturer and Model: Spectrum Controls 1769SC-IF4IH
2. Analog Output:
a. Outputs: 4 differential 4-20 mA (isolated) with HART communications
b. Resolution: 16-bit (unipolar)
c. Installation: PLC DIN rail. Provide all DIN rail and mounting hardware.
e. Manufacturer and Model: Spectrum Controls 1769SC-OF4IH
3. Discrete Input:
a. Inputs: 8 general purpose ON/OFF, 120 VAC (isolated). Each of the 8
inputs shall be capable of being addressed individually.
b. Installation: PLC DIN rail.
c. Manufacturer and Model: Allen-Bradley 1769-IA8I
4. Discrete Output:
a. Outputs: 8 isolated dry contact relay output. Contacts rated for 2 amps at
120 VAC. Install surge protection on all outputs and provide AllenBradley recommended parts.
b. Installation: PLC DIN rail
d. Manufacturer and Model: Allen-Bradley 1769-OW8I
5. All I/O modules shall be supplied with Allen-Bradley removable terminal blocks
that plug into the front of the I/O module.
6. Provide minimum 20% spare installed I/O for each type of installed I/O.
7. Provide minimum 25% spare space on every DIN rail for future expansion.
8. All I/O, including spares, shall be wired to terminal blocks prior to
interconnection with other devices. See Part II, Section 5.1 – Panel Construction;
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Paragraph E.3, for terminal requirements.
9. Order with conformal coating (“K” designation) when available.
E.
Software:
1. Provide a licensed copy of all programming and configuration software to the
District, including electronic and hard copies of all manuals. The following
software packages shall be furnished in addition to all other software necessary
for the proper programming and configuration of the PLCs and their components:
a. RS Logix 5000
b. RS NetWorx for ControlNet
c. RS NetWorx for DeviceNet
d. RS Linx
e. FactoryTalk View ME
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2.2.E - Rockwell Packaged CompactLogix with Embedded I/O
Detailed Specifications
A.
Applications:
1. The Package CompactLogix series is used for applications such as the rain
gauges.
2. Embedded I/O Capacity: Sixteen (16) 24 VDC discrete inputs, sixteen (16) 24
VDC discrete outputs.
3. Expansion I/O Module Capacity: minimum of two.
4. Installation: DIN rail.
5. Communication Ports: One (1) RS-232 serial port (DF1 or ASCII) and one (1)
Ethernet I/P port.
6. Manufacturer and Model: Allen-Bradley Packaged CompactLogix 1769-L24ERQB1B, or current model.
7. Programming Software: Rockwell RSLogix 5000. IEC 61131-6 compliant.
8. Order with conformal coating (“K” designation) when available.
B.
Network Communications:
1. Ethernet I/P – use port on processor.
C.
Power Supplies:
1. PLC Power:
a. Manufacturer and Model: Allen-Bradley 1769-PA4K.
b. Order with conformal coating (“K” designator) when available.
2. Field Devices: Provide power supplies to power field devices that require 24
VDC. Mount next to modules.
a. Input Voltage: 120 VAC, 60 Hz
b. Output Current: Sized for loads at 24 VDC with 25% spare capacity.
c. Provide cables and fusing
d. Manufacturer and Model:
1) Allen-Bradley 1606-XLS Performance Series
D.
I/O Requirements:
1. All I/O modules shall be supplied with Allen-Bradley removable terminal blocks
that plug into the front of the I/O module.
2. Provide minimum 20% spare installed I/O for each type of I/O.
3. Provide minimum 25% spare space in every panel for future expansion.
4. All I/O, including spares, shall be wired to terminal blocks prior to
interconnection with other devices. See Part II, Section 5.1 – Panel Construction;
Paragraph E.3, for terminal requirements.
E.
Software:
1. Provide a licensed copy of all programming and configuration software to the
District, including electronic and hard copies of all manuals. The following
software packages shall be furnished in addition to all other software necessary
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for the proper programming and configuration of the PLCs and their components:
a. RS Logix 5000
b. RS Linx
c. FactoryTalk View ME
2.2.F - Operator Interface Terminals (OIT):
Notes to specifier:
Operator Interface Terminals (OITs) shall be used as the interface to the process control system
for a specific subsystem or particular process, as shown on the Contract Drawings or
specifications. All OITS shall be functionally similar as to display arrangements, menu
selections, command terminology, and data access methods. All OITs shall be programmed
using the District-developed object library.
All OITs of a given type shall be functionally interchangeable differing only in the configuration
installed on each type. All OITs shall be capable of accessing typical operator process control
functions. Each OIT’s functional environment shall be password-protected for system security
and user identification. Required number of OITs provided shall be as shown or specified.
It is the District’s intention to have the PLC/PanelView OIT Ethernet network separate from the
PLC/HMI control Ethernet network. This requires multiple Ethernet modules in the PLC rack.
For new PanelView installations the PanelViews shall be 24 VDC powered and typically UPS
backed-up. For replacement of existing 120 VAC PanelViews, consult the District.
Bid specifications must list the required display size for each application. The only approved
display sizes are listed below.
Use the “Type A” OIT only for very large process systems or units and/or complex systems that
require detailed graphics and overview screens. Use the “Type B” OIT for medium-sized
processes or units with only moderately complex graphics and overview screens. Use the “Type
C” OIT for small or simple processes or units. Typically used for small packaged or vendorsupplied panels.
All OITS shall be provided with conformally-coated electronics for the screens and logic
modules. All specifications below shall be considered minimum requirements to allow for
manufacturer improvements.
A.
“Type A” OIT:
1. Manufacturer and Model: Allen-Bradley PanelView Plus 6 or latest series,
catalog number 2711P-B15C4D9, without equal.
2. Display Screen Size: 15 inches, diagonally measured, backlit.
3. Resolution: 1024 x 768 pixels, 18-bit color graphics.
4. Display and Keypad Type: Touch screen and keypad.
5. Memory: 512 MB RAM and 512 MB nonvolatile flash memory.
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6.
7.
8.
9.
Provide extended features and file viewers.
Supply Voltage: 24 VDC (see Note to Specifier).
Communications: Ethernet and RS-232.
Mounting: OIT shall be mounted on the front face of panel, as indicated on the
Drawings.
10. Provide six (6) Allen-Bradley supplied protective overlays for screen and keypad.
11. Provide all cables, interface cards, local circuit breaker, and wiring.
12. Provide conformal coating of all circuit boards, including screen and logic
module, when option is available.
B.
“Type B” OIT:
1. Manufacturer and Model: Allen-Bradley PanelView Plus 6 or latest series,
catalog number 2711P-B12C4D9, without equal.
2. Display Screen Size: 12.1 inches, diagonally measured, backlit.
3. Resolution: 800 x 600 pixels, 18-bit color graphics.
4. Display and Keypad Type: Touch screen and keypad.
5. Memory: 512 MB RAM and 512 MB nonvolatile flash memory.
6. Provide extended features and file viewers.
7. Supply Voltage: 24 VDC (see Note to Specifier).
8. Communications: Ethernet and RS-232.
9. Mounting: OIT shall be mounted on the front face of panel, as indicated on the
Drawings.
10. Provide six (6) Allen-Bradley supplied protective overlays for screen and keypad.
11. Provide all cables, interface cards, local circuit breaker, and wiring.
12. Provide conformal coating of all circuit boards, including screen and logic
module, when option is available.
C.
“Type C” OIT:
1. Manufacturer and Model: Allen-Bradley PanelView Plus 6 or latest series,
catalog number 2711P-B7C4D9, without equal.
2. Display Screen Size: 6.5 inches, diagonally measured, backlit.
3. Resolution: 640 x 480 pixels, 18-bit color graphics.
4. Display and Keypad Type: Touch screen and keypad.
5. Memory: 512 MB RAM and 512 MB nonvolatile flash memory.
6. Provide extended features and file viewers.
7. Supply Voltage: 24 VDC (see Note to Specifier).
8. Communications: Ethernet and RS-232.
9. Mounting: OIT shall be mounted on the front face of panel, as indicated on the
Drawings.
10. Provide six (6) Allen-Bradley supplied protective overlays for screen and keypad.
11. Provide all cables, interface cards, local circuit breaker, and wiring.
12. Provide conformal coating of all circuit boards, including screen and logic
module, when option is available.
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2.2.G - Software and Programming:
A. Contractors, system integrators and in-house programmers that perform work
involving any portion of the District’s process control system must first verify that
they are working with the latest version of custom PLC control logic and all other
custom and standard software as the basis for their control system augmentation,
work. Verification of versions should be confirmed by District personnel.
B.
Provide the initial programming and system configuration for all PLCs, HMIs, OITs
and servers required to make the system(s) function in accordance with the contract
documents, subsequent control system and control strategy workshops, and submittal
review comments. Provide electronic copies of all documentation describing the
programming and database developed for the project including but not limited to:
1. Control logic listings with detailed descriptions for each rung, function, module,
etc.
2. Register content tables
3. System configuration information
4. Other documentation as described herein.
C.
Provide updates to the software programming including all updated documentation to
reflect all factory and field changes, modifications, system debugging, etc. required
during design, factory testing, jobsite start-up, training, operational demonstration,
and operation by District personnel up to and including the issue of the Certificate of
Substantial Completion or the end of the Post-Commissioning Services period as
applicable to the Project.
D.
The District’s process control system Change Management and Version Control
standards must be adhered to. Software and programming revisions, updates, and
patches shall be continuously managed and documented through the duration of the
project. The objective of version control and change management is to ensure that
all programs reside in the equipment for which they are intended, and that those
versions are properly authorized and up-to-date.
E.
Project software and programming version control shall be implemented using the
District’s Rockwell Software FactoryTalk AssetCentre application or other
application acceptable to the District. When initial or revised versions of software
are implemented, the person archiving the version shall include notations that
identify the project name and number, program name, PLCs/OITs affected,
software/program name, version number, name of person authorizing the version,
name of programmer, version release date, description of the issues addressed by the
version and version distribution/commissioning date. Refer to Sections 2.0 and 2.1
of the NEORSD Standard Object Library Guideline for additional details regarding
software version control.
F.
Programming and software of PLCs and Operator Interface Terminals programmed
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under the contract shall be fully compatible with one another and shall be developed
using the RS Logix family series software by Allen-Bradley. Provide licensed copies
of all programming configuration, system, vendor, and third party applications
software to the District, for all control system software products provided under the
Contract.
G.
Provide electronic and hard copies of all manuals.
H.
Refer to the PLC Standards sections for ControlLogix and CompactLogix for the
required software.
I.
Licensed copies of all other software necessary for the proper programming and
configuration of the PLCs and their components shall also be supplied.
References
A.
Reference Part II, Section 5.1, Panel Construction.
Installation Details
A.
B.
Reference Part II, Section 5.1, Panel Construction
The PLC and I/O racks shall be installed such that all LED indicators and switches
are readily visible with the panel door open and such that repair and/or replacement
of any PLC component can be accomplished without disconnecting any wiring or
removing any other components.
Section 2.3 - Panel Wiring
This section provides the detailed requirements for the wiring of PLC panels. Included in this
section are wire details as follows:
A. Wire Types
B. Color Standards
C. Wiring Separation Distances
D. Wire Tagging and Labeling
E. Grounding
2.3.A - Wire Types:
1. Internal panel wiring shall be Type THHN stranded copper wire with thermoplastic
insulation rated for 600 V at 85 C for single conductors, color coded and labeled
with wire identification.
2. For internal panel DC signal wiring, use No. 18 minimum AWG shielded. For DC
field signal wiring, terminal strips shall be capable of handling No. 12 wiring
(minimum).
3. For internal panel AC power wiring, use No. 12 minimum AWG. For AC signal
and control wiring, use No. 16 minimum AWG. For wiring carrying more than 15
amps, use sizes required by the NEC.
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2.3.B - Color Standards
1. 120/208 Volt Systems (includes control power):
a. Hot: Black
b. Neutral: White
2. AC Control Wiring: Red
3. DC Control Wiring: Blue
4. Grounding Conductors: Green
5. All wiring not de-energized by the panel disconnect or circuit breaker shall be
yellow wire.
a. For all panels containing wiring not de-energized by the panel disconnect or
circuit breaker, provide a warning nameplate on the front of the panel stating
"WARNING: YELLOW WIRING NOT DE-ENERGIZED BY PANEL
DISCONNECT". The nameplate shall be amber with black ¼-inch high letter
engravings and shall be attached to the panel face with stainless steel screws
2.3.C - Wiring Separation Distances
1. AC power wiring (120 volts and greater) and signal wiring shall be separated within
the panel by the following distances. Signal wiring shall include control and
monitoring wiring with voltage levels from 0 to 120 V AC/DC. Included are
analog, discrete, bus (DeviceNet, Fieldbus, etc), and communications wiring
(ModBus, Ethernet, etc.)
Separation Distances
Voltage
0 to 125 volts
125 to 250 volts
250 to 480 volts
Current
0 to 10 amps
1 to 50 amps
0 to 200 amps
Minimum Distance Between
AC Power Wiring and Signal
Wiring
12 inches
15 inches
18 inches
2.3.D - Wire Tagging and Labeling
1. Wires shall be identified at each end with permanent number codes.
2. Where practical, wire numbers shall be unique and continuous. Where wire
numbers change, the appropriate drawings shall include both wire numbers, clearly
indicated, at the point of transition.
3. Each wire number shall be solid, machine printed, and shall not be pieced from
other single and/or double-digit tags.
4. Wire markers shall be heat, oil, water, and solvent resistant, vinyl, self-laminating,
self-adhesive, wrap type labels as manufactured by the W.H. Brady Co. or approved
equal.
5. All wire labels shall be clearly visible and not hidden by wire duct or other
components in the enclosures.
6. PLC panel wire tagging shall be in accordance with Part IV Appendix Sections 1.0
and 2.0.
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2.3.E – Grounding
1. Shields
a. Shields shall be connected to panel isolated ground bus. The isolated ground
bus shall be attached to building steel.
2. Neutrals / Returns
a. Neutrals / returns shall be attached to terminal blocks which are connected to
the panel neutral bus. The panel neutral bus shall be connected to the
uninterruptible power supply.
Reference Standards
A. Reference Part II, Section 5.1, Panel Construction
Installation Details
A. Reference Part II, Section 5.1, Panel Construction
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Section 2.4 - Panel Components
2.4.A - Power Distribution Terminal Blocks
1. Provide copper power distribution blocks according to drawings or sized to meet
application. Provide Square D Class 9080-LBC series or approved equal. Provide
clear plastic covers for terminal blocks to prevent incidental contact with terminals.
2.4.B - Terminal Blocks
1. Terminate all field wiring and internal panel wiring at screw type, feed-through
terminal blocks. Provide gray terminal blocks unless otherwise specified or shown
on drawings. Provide Allen-Bradley Catalog number series 1492-J* or approved
equal. Adjust catalog number for wire sizes used. For example, for wire size range
from 22 AWG to 10 AWG use Allen-Bradley Catalog No. 1492-J4 or approved
equal.
2. Terminal blocks shall be UL/CSA approved with a 600 volt rating.
3. All terminal blocks shall have finger-safe terminals.
4. Mount terminals on rigid, high rise aluminum DIN rail. Use Allen-Bradley Cat. No.
1492-DR6 or approved equal.
5. Heavy-duty end anchors shall be provided on both ends of all terminal strips to
firmly anchor the terminal blocks to the mounting rail and insulating end barriers
shall be provided on one end of the terminal strip, as necessary.
6. No more than two wires shall be terminated at any single screw. Provide jumpers as
required to join adjacent terminal blocks for additional wiring connection points.
7. All terminal blocks shall be labeled with alpha or numeric identifiers on each block.
Identifiers shall be pre-printed snap-in marker cards.
8. Provide a separate terminal block for landing each analog signal cable shield.
9. Provide separate terminal strips with minimum physical separation for DC signal
and AC power wiring. Maintain minimum physical separation between signal and
power wiring. See Part 2, Section 2.3 for separation distances.
10. Provide spare terminal blocks equal in number to 20 percent of the terminals used
for each type of wiring (for example, signal and power). Mount on DIN rail. Wire
all spares from I/O card termination arms to the interposing terminal blocks.
2.4.C - Fused Terminal Blocks
1. Provide screw type, fused terminal blocks for all wiring powered from within panels
or enclosures or to devices located outside the panel or enclosure. Provide black
terminal blocks unless otherwise specified or shown on drawings. Fused terminal
blocks shall be Allen-Bradley catalog number series 1492-H* or approved equal
with blown fuse indication (LED preferred when available). For example, for 1/4”
x 1 – 1/4” fuse size and 10 to 57 V AC/DC service use 1492-H5 with LED indicator
and for 100 to 300 V AC service use 1492-H4 with Neon indicator or approved
equal.
2. Fused terminal blocks shall be UL/CSA approved with a minimum 300 volt rating.
3. All terminal blocks shall have finger-safe terminals.
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4. Mount terminals on rigid, high-rise aluminum DIN rail. Use Allen-Bradley Cat. No.
1492-DR6 or approved equal.
5. Heavy-duty end anchors shall be provided on both ends of all terminal strips to
firmly anchor the terminal blocks to the mounting rail and insulating end barriers
shall be provided on one end of the terminal strip, as necessary.
6. No more than two wires shall be terminated at any single screw. Provide jumpers as
required to join adjacent terminal blocks for additional wiring connection points.
7. All terminal blocks shall be labeled with alpha or numeric identifiers on each block.
Identifiers shall be pre-printed snap-in marker cards.
8. Provide separate terminal strips with minimum physical separation for DC signal
and AC power wiring. Maintain minimum physical separation between signal and
power wiring. See Part 2, Section 2.3 for separation distances.
9. Provide fuses (sized as required) and fuse pullers for all fused terminal blocks.
10. Provide 20 percent spare fused terminal blocks mounted on the rail(s). Wire all
spares from I/O card termination arms to the fused terminal blocks.
2.4.D - Control Relays
1. Type: General purpose, plug-in type rated for continuous duty.
2. Performance and Construction Requirements:
a. Coil Voltage: 120 VAC or 24 VDC, as required.
b. Contact Configuration: Minimum DPDT with at least one spare contact. If
4PDT relay is required, then see Item # 4, below.
c. Contact Material and Rating:
1) General Use: Silver or silver cadmium oxide contacts rated for 10
amps minimum (DPDT) at 120 VAC.
2) Low Power Switching: Fine silver, gold flashed contacts specifically
designed for low power switching, rated for 2 amps minimum at 30
VDC. Idec series RY or approved equal. Consult the Engineer.
d. Mounting: 8-Pin or 11-pin octal base plug-in sockets for sub-panel mounting
on DIN rail. Sockets shall have screw terminals for wiring connections which
shall accept a minimum of two #14 AWG wires. (Four pole relays as in
paragraph #4, below, shall be supplied with a matching blade-style socket.)
Sockets shall have finger-safe terminals.
e. Cover: Clear plastic dust cover.
f. Indication: LED indicator light.
g. Accessories: Hold-down spring or clip.
h. Accessories: MOV for DC voltage coil and MOVs for contacts, as required.
i. Accessories: MOV or zener diode for AC voltage coil, MOVs for contacts, as
required.
j.Approvals: UL recognized.
3. Manufacturer and Model:
a. Tyco / Potter & Brumfield KRPA series.
b. Allen-Bradley 700-HA series
c. Magnecraft / Struthers-Dunn 750 series
d. Or approved equal.
e. Order with conformal coating when available.
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4. Manufacturer and Model (If 4PDT relay required):
The following relays come with blade-style terminals:
a. IDEC RH4B series.
b. Magnecraft / Struthers-Dunn 784XDXM4L full-featured series.
c. Allen-Bradley 700-HC2 series.
d. Square D 8501RS series.
e. Or approved equal.
f. Order with conformal coating when available.
2.4.E - Timing Relays
1. Type: Programmable, multi-function, multi-range plug-in type time delay relay
providing delay-on-make, delay-on-break and interval operation. Time shall be
adjusted with a thumbwheel or digital display and not a rotary knob.
2. Construction Features:
a. Time range: 0.1 seconds or less to 9990 hours or more
b. Digital setting accuracy: Five percent or better
c. Contacts:
1) Type: DPDT
2) Rating: 10 Amp minimum
d. Housing: Plug-in design with dust and moisture-resistant molded plastic case.
e. Power input: 24 to 240 V AC or DC.
f. Operating Temperature: -10º C to +55º C.
g. Unit shall have LEDs or LCD to show timing status.
h. Sockets: 11-pin octal base to match relay. DIN rail mount. Sockets shall have
screw terminals for wiring connections which shall accept a minimum of two
#14 AWG wires. Sockets shall have finger-safe terminals.
i. Hold-down clips
j. Suppression diode or current snubber, as required
k. Approvals: UL recognized.
3. Manufacturer and Model:
a. Magnecraft TDRPRO 5100 series
b. Tyco / Potter & Brumfield CNT-35-96
c. Or approved equal.
d. Order with conformal coating when available.
2.4.F - Panel-Mounted Operators and Pilot Lights
1. All panel-mounted operators including, but not limited to, pilot lights, pushbuttons,
selector switches, stations, specialty operators, and potentiometers shall be the
NEMA 30.5 mm type.
2. Pushbuttons – General Purpose Areas
a. Nema 4X watertight & oiltight
b. Non-illuminated
c. Momentary contact unless otherwise specified
d. 1 N.O & 1 N.C. contact unless otherwise specified
e. Standard aluminum, Nema 4 grey legend plate unless otherwise specified
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1. Manufacturer and Model:
a. Allen-Bradley 800H series
b. Or approved equal
f. Nameplate, laminated plastic, black letters on white; text as specified
3. Pushbuttons – Hazardous (NEC classified) Locations
a. Nema 7/9 for Division 1 and Division 2 Areas
b. Non-illuminated
c. Momentary contact unless otherwise specified
d. 1 N.O & 1 N.C. contact unless otherwise specified
e. Standard aluminum, Nema 4 grey legend plate otherwise specified
1) Manufacturer and Model:
a. Allen-Bradley 800H series
b. Or approved equal
f. Nameplate, laminated plastic, engraved black letters on white; text as specified
Pushbutton Styles and Colors
Function
Start
Stop
Emergency Stop
All Other Functions*
*Unless otherwise specified.
Style
Flush
Extended
Mushroom
Flush
Operator Color
Green
Red
Red
Black
4. Pilot Lights – General Purpose Areas
a. Nema 4X watertight and oiltight
b. Full voltage, push-to-test, LED lamp
c. Voltage to match application
d. Standard aluminum, Nema 4 grey legend plate unless otherwise specified
1. Manufacturer and Model:
a. Allen-Bradley 800H series
b.Or approved equal
e. Nameplate, laminated plastic, engraved black letters on white; text as specified
5. Pilot Lights – Hazardous (NEC classified) Locations
a. Nema 7/9 for Division 1 and Division 2 Areas
b. Full voltage, push-to-test, LED Lamp
c. Voltage to match application
d. Standard aluminum, Nema 4 grey legend plate unless otherwise specified
1) Manufacturer and Model:
a. Allen-Bradley 800H series
b.Or approved equal
e. Nameplate, laminated plastic, engraved black letters on white; text as specified.
Function
Power
Part II – Standards and Conventions
Pilot Light Colors
Color
Examples
White
Panel power on, control power on
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Status
Alarm or Fault
Energized
De-Energized
Blue
Amber
Red
Green
In remote, In calibration
VFD fault, low level, high pressure
Motor or pump running, valve open
Motor or pump stopped, valve closed
6. Selector Switches – General Purpose Areas
a. Nema 4X watertight and oiltight
b. Non-illuminated
c. Number of positions to suit application
d. Maintained or spring return to suit application
e. 2 N.O. and 2 N.C. contacts unless otherwise specified
f. Standard knob lever with black knob and white insert unless otherwise
specified
g. Standard aluminum, Nema 4 grey legend plate unless otherwise specified
1) Manufacturer and Model:
a. Allen-Bradley 800H series
b.Or approved equal
h. Nameplate, laminated plastic, engraved black letters on white; text as specified
7. Selector Switches – Hazardous (NEC classified) Locations
a. Nema 7/9 for Division 1 and Division 2 Areas
b. Non-illuminated
c. Number of positions to suit application
d. Maintained or spring return to suit application
e. 2 N.O. and 2 N.C. contacts unless otherwise specified
f. Standard knob lever with black knob and white insert unless otherwise
specified
g. Standard aluminum, Nema 4 grey legend plate unless otherwise specified
• Manufacturer and Model:
a. Allen-Bradley 800H series
b.Or approved equal
h. Nameplate, laminated plastic, engraved black letters on white; text as specified
Reference Standards
A. Reference Part II, Section 2.1, Panel Construction and Part II, Section 2.2, PLC
Hardware & Software.
Installation Details
A. Reference Part II, Section 2.1, Panel Construction.
B.
The PLC and I/O racks shall be installed such that all LED indicators and switches
are readily visible with the panel door open and such that repair and/or replacement
of any PLC component can be accomplished without disconnecting any wiring or
removing any other components.
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SECTION 3 - PLC PROGRAMMING STANDARDS
Section 3.0 - Introduction
With over 50 PLCs deployed at one plant alone, it is not possible for an individual to retain
detailed knowledge about all the PLCs in place. Standard ranges and schemes are necessary to
keep some uniformity among the ladder logic and files. Almost all PLCs have some control
outputs; very few are used only for monitoring.
Section 3.1 - Allen Bradley PLC 5 Programming Conventions
Almost all plant process PLCs are Allen-Bradley PLC-5, and all that are connected to the
Control Network are Ethernet processors, e.g., PLC 5-60E. Data Highway+ cabling is used to
connect remote I/O and a small amount of Flex I/O to the processors. Extended I/O is not used.
Future purchases of new PLC equipment (not add ons to existing PLC 5s) will be Rockwell
ControlLogix.
3.1.A - I/O Ranges
I/O addresses are fixed by A-B rack numbers and slot numbers. Inputs are usually arranged in
the lower racks, with digitals preceding analogs. Complementary I/O is not to be used. I/O is
arranged to concentrate related inputs or outputs on single cards so that an I/O card failure will
affect only one or two pieces of equipment, i.e., all start/stop/run/fail signals for a given pump
are on the same card. However, spare or backup equipment shall be entirely wired to separate
I/O cards to avoid losing both pieces of equipment if there is an I/O card failure. In most cases,
spare inputs and outputs are designed in.
Thorough annotation is required for I/O rack numbers as part of the program documentation. In
existing PLCs, an operator interface often takes a rack number in the middle of remote I/O rack
numbers.
3.1.B - Block Transfer Ranges
Several types of block transfers are used, a) analog inputs, b) remote or flex I/O transfers, c) data
transfers from other PLCs and operator interfaces. Polling files are discussed in a different
section.
Analog input transfers, remote I/O, and flex transfers are generally transferred to file BT:0 and
up. Thorough annotation is required. Transfers to operator interfaces do not have standard files,
but must be thoroughly annotated. Internal ladder transfers are as required.
3.1.C - HMI Polling Files
Data to be polled by the HMI system is transferred to the N:80 file. If there is an existing PLC
that already has an N:80, N:180 is used. The data is aggregated to minimize network traffic,
since the data can be read contiguously. Analog values in general are posted to the transfer file
as 0-4095 values with scaling done at the HMI server. Double-precision values are posted to the
F:8 file. Control outputs from the HMI system are sometimes posted to the B:3 file, but must be
thoroughly annotated.
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3.1.D - Remote I/O Addressing
Remote I/O rack addressing is not standardized. Thorough annotation is required.
3.1.E - Flex I/O Addressing
Flex I/O is used very little at this time. Addressing is not standardized so thorough annotation is
required.
3.1.F - Software
Allen-Bradley RSLogix 5, RSLogix 500, RSLinx, and PanelBuilder software from Rockwell
Automation are used exclusively for programming and building interfaces. The software
package and its application are listed below:
Software
RSLogix 5
RSLogix 500
RSLinx
PanelBuilder
Application
PLC-5 programming
SLC 500 series programming
View active networks and run multiple applications
PanelView HMI configuration
Third party applications, such as Taylor software, are not to be used.
New PLC programs or modifications to existing PLC programs shall be executed using software
compatible with existing development software used by the NEORSD. New or modified
programs developed for the NEORSD using versions of software that are later than versions of
software owned by the NEORSD shall be unacceptable. It shall be the responsibility of the
programmer to determine the existing version of development software used by the NEORSD.
Contractor’s integrator shall contact the plant electrical-instrumentation (EIT) manager or the
District Manager of Process Control and Automation to acquire the latest copy of the affected
PLC program to be modified under the integrators contract responsibility. All program
modification that involves new hardware or system add-ons shall be done in a separate
subroutine. Each rung shall be described as to function, and each element in the rung shall have
a description. If modifications to existing equipment in the system are part of the integrators
responsibility, the modifications shall be done in the existing subroutine. Each rung shall be
fully described, and each element in the rung shall have a description. NEORSD-provided tag
names or naming conventions shall be used.
Any additions to the I/O subsystem shall have the element added to the I/O configuration portion
of the RSLogix software. As program changes are made, the daily-modified software shall be
presented in soft copy to the plant EIT manager. When program modifications are complete, the
software in soft copy shall be presented to the plant EIT manager as well as the District
Manager of Process Control and Automation.
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Section 3.2 - Allen-Bradley SLC 500 Programming Conventions
SLC 500 PLCs will follow PLC-5 conventions, but are not in use currently except as part of
equipment packages. The District is evaluating installation of SLC 500s at collection system
sites. RSLogix 500 software will be used.
All new PLCs purchased will be Rockwell ControlLogix.
Section 3.3 - Allen Bradley Operator Interface
Allen-Bradley Color LCD PanelView Plus 6 graphic terminals must be used for non-HMI
operator interface terminals (OIT).
The PLC/OIT network shall be separated from the PLC/HMI control network. This will require
multiple Ethernet modules in the PLC rack.
Since models change with relative frequency, contact your NEORSD project manager for
information regarding PanelView specifications.
Transfer Ranges To/From PLC (PLC5/SLC500 Only)
Operator Interface rack addressing is not standardized. Thorough annotation is required.
Software
Panel Builder from Rockwell Automation is required for applications programming. Thorough
documentation and annotation is required.
Section – 3.4 - Other PLC Programming Conventions
Section to be completed if the District retains the few other PLCs it has (General Electric,
Modicon).
(Contact the District Manager of Process Control and Automation if reprogramming of existing
GE PLCs is required)
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Section 3.5 - Analog Rounding/Truncation Logic
3.5.A - General
Truncating logic provides a standard method for indication with a set resolution, and storage of a
logged value into the data warehouse used for reporting.
All analog (unit of measure) values need to be in the form of a REAL type or “Float” for the
HMI system. The PLC5 defines a float [by default]
F8 Floating
Point
This file stores a # with a range of 1.1754944e-38 to
3.40282347e+38
It’s this expansive precision, that when passed though the various systems, can result in
unpredictable rounding and trailing digits. The value stored in one database or warehouse may
not exactly match another or the raw data. Due to the amount of stored data and the duration of
queries performed against the data, these seemingly slight differences have a large impact on
reports’ final values.
The solution is limiting the precision (Truncating) at the original point source of the signal or
calculation within the Programmable Logic Controller (PLC). The logic presented here is
standard for SLC and PLC5 legacy platforms; the ControlLogix PAC platform does not require
truncating logic. There are three methods of logic used to accomplish the truncating operation:
The most common is defined in Table 1.a. This is used when the intermediate integer value has
a scaled range under 32767.
The second most used is defined in Table 1.b. This is used when whole numbers, or integers,
with no precision are to be logged to the data warehouse.
The third is defined in Table 1.c. This is used when the intermediate integer value has a scaled
range exceeding 32767.
The PLC5 defines an integer [by default] as having only 15 useable bits to the word and the 16th
determining the sign +/- of the value.
N7 Integer This file is used to store bit information or numeric values with
a range of -32767 to 32768.
3.5.B - Background
Process variables from various sources in SCADA, such as a PLC, which are used for data
analysis in existing and upgraded databases as presented to the SCADA system, have
consistency errors during data analysis.
Process variables, when stored historically with a long number of digits after the decimal point,
are in fact interpreted differently by various platforms and users. These interpretations whether
automated or user directed present rounding errors when converting between platforms.
Overall these data analysis errors create reporting discrepancies. These errors can end up being
significant over a long period of time. In other words, two users can interpret the identical data
differently.
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It has been determined that limiting process variables at the HMI level is not possible. The
displayed value can be limited but the background raw data value used for reporting is always
the full floating point value.
3.5.C - General Solution
The solution is to promote the use of defined process variable precision at the local level and
then propagate the process variable up through the SCADA hierarchy. This process uses the
same value as a consistent reference across all SCADA systems including control, monitoring,
historical and reporting from the base PLC level and up. The value, once defined in the PLC,
will be used as follows:
•
•
•
•
•
PLC Process Variable, within PLC for all PLC process control logic including process
calculations and messages between PLCs.
OIT Process Variable, for display in the local PLC monitoring and control equipment.
HMI Process Variable, for display in SCADA monitoring and control equipment
Historical Process Variable, for storage in historical database.
Reporting Process Variable, for reports from historical databases.
The process variable with defined precision will be referred to as the Truncated Value herein.
This truncation logic is specific for PLC5s, but can be converted for use with ControlLogix PLCs
into the form of an AOI. Essentially the PLC5 logic described herein functions similarly to an
AOI.
Rounding built into the truncation logic is based on IEEE 754-2008 standard practices for
rounding.
The PLC5 logic uses a subroutine with passed parameters and a returned value. There is no
indirect addressing which can lead to overlapping registers which would produce “junk” data.
The logic is designed to process all numbers without creating PLC overflows or errors. The logic
design prevents errors by checking the variables against defined limits.
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3.5.D - Implementation
The logic is implemented in three steps for integrators to follow when applying the Truncated
Value logic.
Step 1: Configure two data files
N700 – ROUNDING_I provide with 10 words
F800 – ROUNDING_F provide with 10 words
Use the predefined words in the truncating logic standard which will, on import, fill their
descriptions into the N700 and F800 data files.
Table 1
Step 2: Insert Rounding Program
The logic will be standard and is to be used in all PLC5s implementing this Truncated Value
solution. The logic will be its own subroutine. Create a new program file, whichever is the next
available (the file number is irrelevant), but it must be the last in the program files. Call the new
program file “FL_ROUND.” Import the truncating logic into the newly created ladder program.
Once the new program file is created the JSR block parameter for jumping to the truncating logic
can be set. All subsequent JSRs for the truncating logic in the PLC program will now reference
this new program file.
Note: The PLC5 inherent logic converts any number above 9,999,999.0 to an exponent number.
For example the number 10,000,000 is automatically converted to 1E7. Similarly, for negative
numbers, the number -10,000,000 is automatically converted to -1E7. These numbers are passed
through the truncating logic input to output. These limitations can be prevented by
understanding your data and the data’s potential range.
Next program
ladder available.
Table 2
Note: DO NOT INSERT IF THERE ARE OPEN PROGRAM FILES!
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FT_ROUND SHALL BE THE LAST PROGRAM FILE WHEN ADDED TO THE
PROGRAM.
Step 3: Insert JSR program blocks
The Jump to Subroutine (JSR) block is positioned after an analog scaling compute block. This
truncating logic standard does not cover or replace the scaling practices in the compute block.
A scaling compute block will produce a float which is the raw unrounded floating point value.
The scaling compute block output is to be used as the truncating subroutine input. The scaling
compute block floating point number is to have at the end of its description the text “RAW” to
identify it as the unrounded process variable. For example, description is “Raw Sewage Wet
Well Level 0-30 FT (RAW)”
The scaling and truncating is expected to be performed before transfer to the Program file N80 –
HMI program file for consistency.
The Jump to Subroutine block is a two input and one output block.
Input 1 (FLOAT_IN): The RAW real floating point number (Unrounded)
Input 2 (DEC_RIGHT): Desired amount of digits to the right of the decimal point.
Output 1 (FLOAT_ROUNDED): Rounded Floating Point number (Truncated Value)
There is one additional parameter, the program file number. The program file number is assigned
according to directions in Part 2.
For Input 2, the Truncated Value only has four choices allowed for rounding. Any numbers used
outside of these for numbers will default back to these numbers. For example, if “-3” is entered
the program will operate as if a “0” was set at the input. The same goes for numbers greater than
three. For example, if “12” is entered. The program will operate as if a “3” was set as the input.
For standard programming only use the following values:
•
•
•
•
“0” returns a whole number. i.e. 7.501832 returns 7
“1” returns one digit to the right of the decimal point. i.e., 7.501832 returns 7.5
“2” returns two digits to the right of the decimal point. i.e. 7.501832 returns 7.50
“3” returns three digits to the right of the decimal point. i.e. 7.501832 returns 7.502
The Output is self explanatory and is the desired result for the defined process variable and
desired precision level. The description of the truncated value will be, following our example
from above, “Raw Sewage Wet Well Level 0-30 FT”, see Figure 1 below.
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Figure 1
Input 1: Scaled
Analog Channel
input signal
Input 2: Desired
resolution amount
Output 1: Rounded
Floating Point number
(Truncated Value)
Note: ALL CONTROL LOGIC SHALL USE OUTPUT 1 ONLY. Additional CPT and logic
block may be used as long as “Output 1” is referenced and not “Input 1”.
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3.5.E - Ladder Logic – Printed
Below is the printed truncation ladder logic for reference. This code is available from the NEORSD;
contact your project representative for more details.
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SECTION 4 - COMPUTER HARDWARE
Section 4.0 - Introduction
The majority of computer hardware is consistent across viewers, servers, historians and domain
controllers. Differing power supply and hard drive configurations have been implemented for
the servers. The computers can hold two microprocessors, although only one is installed.
Section 4.1 - Area Control Stations (ACS, Viewer)
This section provides the detailed requirements for an ACS. An ACS includes the following:
A. Computer System
B. Monitor
C. Keyboard
D. Enclosure
Detailed Specifications:
4.1.A - Computer System
1. The computers are Compaq Proliant 1600 and have the following components:
a. Pentium II microprocessor (450MHz)
b. 9.1Gb SCSI hot-swappable hard drive in sled
c. Motherboard-mounted SCSI controller and IDE controller
d. Motherboard-mounted Ethernet card, Netelligent 10/100 TX
e. Matrox G200 video card
f. 128Mb RAM
g. CD ROM drive
h. Floppy drive
i. Single power supply
Please note that computer specifications change several times a year as options are changed or
upgraded. This equipment list is correct only at the time of writing. If any computers are to
be procured, please contact the District Manager of Process Control and Automation for
current specifications.
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4.1.B - Monitor
1. The monitors for all operator stations are LCD screens. 18” screens are used in the
ACS cabinets. The longevity and minimal heat dissipation are key factors.
2. Manufacturer: NEC
3. Model: Multisync LCD 1810
4.1.C - Keyboard
1. Hard use keyboards are installed at all operator stations, with an integral pointing
device. The keyboard and pointing device are electrically separate; if one fails the
other may be used to continue operating until repairs can be made. The keyboard is
sized to fit in the drawer of the stainless steel cabinet.
2. Manufacturer: Texas Industrial Peripherals
3. Model number: DT-5K
4.1.D - Enclosure
1. A NEMA 4X stainless steel enclosure with window for the screen and a sealable,
pull out keyboard drawer is used for almost all ACSs.
2. Enclosure shall be lockable using a keyed lockset. All access openings that are
screwed/bolted closed shall use security screws that require a special tool to remove.
3. Manufacturer: Hoffman, or approved equal.
4.1.E - Installation Details
This section does not contain all installation details for the equipment/ system shown, only those
that are required by the NEORSD. These details may exceed those required by the equipment
manufacturer or local codes.
Area Control Stations
Installation details: Use separate flexible conduits to connect network cables, UPS power, and
normal power. Monitor shelf must be set to center the monitor in the window. Power and
network outlets use single-gang boxes mounted to the cabinet.
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Section 4.2 - Area Control Station/Servers (ACS/S)
This section provides the detailed requirements for an ACS/S. An ACS/S is an array consisting
of two (2) computers, installed in a locking cabinet under a counter or desk set to hold the two
monitors. The ACS/S are configured as a redundant server pair in the HMI software and have
communications that will enable data to be served from the redundant if the primary fails. An
ACS/S includes the following:
A.
B.
C.
D.
Computer System
Monitor
Keyboard
Enclosure
Detailed Specifications
4.2.A - Computer System
1. The computers are Compaq Proliant 1600 and have the following components:
a. Pentium II microprocessor (450MHz)
b. Three 9.1Gb SCSI hot-swappable hard drives in sled
c. Smart Array 3200 RAID SCSI controller
d. Motherboard-mounted SCSI controller and IDE controller
e. Motherboard-mounted Ethernet card, Netelligent 10/100 TX
f. Matrox G200 video card
g. 256Mb RAM
h. CD ROM drive
i. Floppy drive
j. Redundant power supplies (three in hot swap configuration)
Please note that computer specifications change several times a year as options are changed or
upgraded. This equipment list is correct only at the time of writing. If any computers are to
be procured, please contact the District Manager of Process Control and Automation for
current specifications.
4.2.B - Monitor
1. The monitors for all operator stations are LCD screens. 20” screens are used in the
ACS cabinets. The longevity and minimal heat dissipation are key factors.
2. Manufacturer: NEC
3. Model: Multisync LCD 2010
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4.2.C - Keyboard
1. Hard use keyboards are installed at all operator stations with an integral pointing
device. The keyboard and pointing device are electrically separate; if one fails the
other may be used to continue operating until repairs can be made. The keyboard is
sized to fit in the drawer of the stainless steel cabinet.
2. Manufacturer: Texas Industrial Peripherals
3. Model number: DT-2000-PS2
4.2.D - Enclosure
1. A lockable enclosure sized for the two CPUs and network hardware. Monitors to be
mounted remotely with keyboards.
4.2.E - Installation Details
This section does not contain all installation details for the equipment/ system shown,
only those that are required by the NEORSD. These details may exceed those required
by the equipment manufacturer or local codes.
A.
Area Control Stations/Servers
1. Installation details: use separate flexible conduits to connect network cables,
UPS power, and normal power. Power and network outlets use single-gang
boxes mounted to the cabinet.
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Section 4.3 - Historians and Domain Controllers
This section provides the detailed requirements for a historian and domain controller. There are
currently two historians and one domain controller per plant. They are not accessed directly by
operators and are for database and administrative functions only. A historian and domain
controller include the following:
A.
B.
C.
D.
Computer System
Monitor
Keyboard
Enclosure
Detailed Specifications
4.3.A - Computer System
1. The computers are Compaq Proliant 1600 and have the following
components:
k. Pentium II microprocessor (450MHz)
l. Three 9.1Gb SCSI hot-swappable hard drives in sled
m. Smart Array 3200 RAID SCSI controller
n. Motherboard-mounted SCSI controller and IDE controller
o. Motherboard-mounted Ethernet card, Netelligent 10/100 TX
p. Matrox G200 video card
q. 256Mb RAM
r. CD ROM drive
s. Floppy drive
t. Redundant power supplies (three in hot swap configuration)
Please note that computer specifications change several times a year as options are changed or
upgraded. This equipment list is correct only at the time of writing. If any computers are to be
procured, please contact the District Manager of Process Control and Automation for
current specifications.
4.3.B - Monitor
1. 17” CRT monitors are used for these computers. Minimum resolution of
1280x1024 and a tight dot pitch are required.
2. Manufacturer: Mag or Compaq
3. Model: Mag 720V or Compaq P75
4.3.C - Keyboard
1. Standard Compaq keyboards and mice are used with these computers.
4.3.D - Enclosure
NA
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Section 4.4 - Printers
This section provides the detailed requirements for printers. There are currently three types
used—report, alarm, and graphics printers (two versions of graphics printers). See the District
Manager of Process Control and Automation for the current requirements and model
numbers.
Detailed Specifications
4.4.A - Report Printer
1. A high durability 600-dot laser printer is required. Print rate is 17
pages/minute. An optional feed tray is attached. An internal MIO card with
Ethernet connection provides connectivity.
2. Manufacturer: Hewlett-Packard
3. Model number: Laserjet 5000N
4.4.B - Alarm Printer
1. A high durability 360x360 dot matrix printer is used. Greenbar tractor feed
paper is required for logging. There is also an integral Ethernet 10/100
connection.
2. Manufacturer: Epson
3. Model number: DFX-5000
4.4.C - Graphics Printer
1. A color inkjet printer is used for screen and trend graph printouts. The printer
has an internal Ethernet module.
2. Manufacturer: Epson
3. Model number: Color Stylus 900N
4.4.D - Mid-size Format Graphics Printer
1. A mid-size (up to C size paper) color inkjet printer used for screen and trend
graph printouts during development. An external HP print server is used to
provide network connectivity.
2. Manufacturer: Epson
3. Model number: Color Stylus 3000
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SECTION 5 - SOFTWARE
Section 5.0 - Introduction
The reader should be aware that software versions are patched and otherwise changed at
intervals as little as weeks. The versions listed below are accurate at the time of writing. If any
software is to be procured, please contact the District Manager of Process Control and
Automation for current specifications.
Section 5.1 - Computer / Network Operating System
The operating system was chosen in tandem with the HMI software. The HMI software chosen
runs only on Microsoft Windows 95/NT at the time of writing. Since the system was required to
use NT Server, the NT domain model was used for the network. A single domain model was
used with the domain master at Southerly and domain backups at Easterly and Westerly. This
scheme along with the IP numbering scheme will allow the entire Control network to be treated
as a single entity when connected by a wide area network. The network is currently
administered as separate networks with intermittent communication between domain servers to
synchronize files, services, and so on.
We are planning to upgrade to Windows 2000 when a version of Cimplicity becomes certified
for use with it. That said, it should also be noted that upgrades and service packs are not applied
without evaluation. Unless there is a defined benefit to move to a certain version or patch level,
the adage “if it ain’t broke, don’t fix it” holds.
At this time (2013), the GE Cimplicity HMI software is being replaced District-wide with
Wonderware HMI. See the District Manager of Process Control and Automation for the
latest developments.
5.1.A - Requirements
The operating system software for the Control network computers is Windows NT 4.0, currently
patched to service pack 4. NT Server is used for the domain server, Oracle application servers,
and ACS/S Cimplicity servers. NT server was required because of the potential for more than 10
computers to be communicating with the server at one time. NT Workstation is used for ACS
viewers.
1. Manufacturer: Microsoft
2. Model number: Windows NT Server, Windows NT Workstation
3. Installation details: NEORSD personnel have a detailed procedure and have saved
partition images which can be used to load servers or workstations. Contact the
District Manager of Process Control and Automation if this work needs to be done.
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5.1.B - Group Management
The NT user management tools such as profiles and policies make it practical to manage users in
groups. In addition to the normal groups (administrators, backups, users, etc), there were two
groups added, HMI users (configuration team members), and HMIopers (operators). The HMI
users are given broad permissions since they configure computers and make changes to systems.
The network administrator id and local administrator ids are separate. HMIopers are guest-level
network ids that have the interface shell set to the Cimplicity HMI viewer application and are
thoroughly restricted.
5.1.C - Security Measures
Several security practices are used, including limitations on file permissions, operator interface
shell substitution, custom policies and profiles, and network permission limitations. A minimum
of 6 characters is required for passwords.
Section 5.2 - Drivers / Utilities Software
5.2.A - ODBC Database Drivers
A third party ODBC driver was required for the interface between Oracle 8 and Cimplicity 4.01.
Merant (formerly Intersolv) ODBC drivers are installed on each computer.
1. Manufacturer: Merant Data Systems
2. Part number: Merant Data Direct 3.50 for Oracle 8, patched to 3.50.0014
3. Installation details: NEORSD personnel have a detailed procedure for loading and
configuring this software. Contact the District Manager of Process Control and
Automation if this work needs to be done.
5.2.B - Hardware Drivers
Several hardware drivers are in use for varying hardware. A list follows. As with the other
software, NEORSD personnel have a detailed procedure for loading and configuring this
software. Contact the District Manager of Process Control and Automation if this work
needs to be done.
1. Compaq Configuration Utility, 4.21
2. Compaq Array Driver / Compaq 2DH Array controller (older)
3. Compaq SmartArray 3200 controller
4. Compaq Netelligent network card driver
5. Matrox Millennium II NT driver (older)
6. Matrox G200 NT driver
7. Compaq power supply viewer
8. Compaq driver for HPC1537A 4mm DAT tape drive
9. Other drivers are in use
5.2.C - Anti-Virus Software
The NEORSD standard anti-virus software is Symantec Norton Anti-Virus (NAV). The control
network uses the anti-virus solution version since it is made for a networked environment. See
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the District Manager of Process Control and Automation for the latest requirements and
version.
1. Manufacturer: Symantec
2. Model number: Norton Anti-Virus Solution 4.0
3. Installation details: NEORSD personnel have a detailed procedure for loading and
configuring this software. Virus definitions are updated regularly and are checked
during the login process. Contact the District Manager of Process Control and
Automation if this work needs to be done.
5.2.D - Printer Drivers
Printer drivers are used for 4 types of printers:
1. HP Laserjet 5000N – Hewlett-Packard PCL 5 driver
2. Epson DFX 5000 – Epson DFX driver
3. Epson Stylus Color 900N – Epson color printing system 3.02
4. Epson Stylus Color 3000 – Epson Stylus Color 3000 driver
5.2.E - Intranet Browser
The Intranet browser is currently not enabled.
5.2.F - Backup Software
Back-up is performed by CA Arcserve IT using the client agents for NT and Oracle and the open
file agent. Backups are currently initiated manually, but will be scheduled regularly after a tape
changer is procured.
1. Manufacturer: Computer Associates
2. Model numbers: Arcserve IT, version 6.61
3. Client Agent for Windows NT, 6.61
4. Backup Agent for Oracle 8, 6.61
5. Backup Agent for open files, 6.61
6. Installation details: NEORSD personnel have a detailed procedure for loading and
configuring this software. Contact the District Manager of Process Control and
Automation if this work needs to be done.
5.2.G - PLC Communications Drivers
Almost all PLCs are Allen-Bradley PLC-5’s. GE Cimplicity uses the RS-Linx driver from
Rockwell Software (and a Cimplicity module in some cases) to communicate with the PLCs.
1. Manufacturer: Rockwell Software
2. Model number: RS-Linx OEM (for ACS/S), 2.10.18
3. RS-Linx full version is used for some development, version 2.10.18
4. There are also GE PLCs attached to the network. No driver software is required for
this communication protocol.
5. There are Modicon PLCs that will be attached to the network. These will not require
a separate driver for the Modbus communications protocol.
6. Installation details: NEORSD personnel have a detailed procedure for loading and
configuring this software. Contact the District Manager of Process Control and
Automation if this work needs to be done.
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Section 5.3 - HMI Software
The HMI software is currently under review for replacement.
Manager of Process Control and Automation for more information.
Contact the District
Cimplicity HMI is used for all human-machine interface (HMI) applications.
5.3.A - Base Product
The base product has all polling, data manipulation, trending, and presentation functions. A
complete software load is performed on all stations with licensing determining the functions
allowed on a given station.
1. Manufacturer: General Electric
2. Version number: Cimplicity HMI 4.0, patched to version 4.01 service pack 3 (4.03)
3. Model numbers: Full Point I/O Development System – IC646TDV000
4. Full Point I/O Runtime System – IC646TRT000
5. Viewer Runtime System – IC646TRT999
6. Installation details: NEORSD personnel have a detailed procedure for loading and
configuring this software. Contact the District Manager of Process Control and
Automation if this work needs to be done.
5.3.B - Additional Applications Modules
Additional application modules provide SPC, pager functions, and server redundancy functions.
For development stations, an Allen-Bradley connectivity module is also required. An ACS/S
server pair requires server redundancy to enable fail over.
1. Manufacturer: General Electric
2. Model numbers: Statistical Process Control – IC646NSP000
3. Cimplicity Pager – IC646NPG000
4. Server Redundancy Option – IC646NHR000
5. Allen-Bradley Communications – IC646NEA000
6. Installation details: NEORSD personnel have a detailed procedure for loading and
configuring this software. Contact the District Manager of Process Control and
Automation if this work needs to be done.
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Section 5.4 - Relational Database
Note: The Cimplicity HMI software is being replaced District-wide with Wonderware
HMI. Contact the District Manager of Process Control and Automation for the latest
developments.
The NEORSD standard relational database is Oracle. The Cimplicity HMI software requires an
external database for trending and some historical functions. Rather than deploy multiple small
databases and maintain them, one larger redundant database per plant was set up to meet the
Cimplicity database needs. It must be redundant because the Cimplicity redundancy requires
separate database names and tables for its primary and redundant servers.
5.4.A - Base Product
Oracle 8 (not 8i) is installed on the control network historians and the information network
ODMS database server.
1. Manufacturer: Oracle
2. Model number: Oracle Enterprise Edition 8.05.0.0
3. Installation details: NEORSD personnel have a detailed procedure for loading and
configuring this software. Contact the District Manager of Process Control and
Automation if this work needs to be done.
5.4.B - Interface to ODMS
Data is passed to the ODMS system via SQL (PL-SQL) calls made from the ODMS to the
historian(s). In many cases, a selection of data is evaluated on the historian and the result is
returned to the ODMS system to limit the amount of data traffic. The ODMS and historians
communicate across a network router set to allow only those PCs to communicate across it.
5.4.C - Interface for HMI Trends
Cimplicity’s trend module uses SQL calls to the historians to select data for display. After the
trend is started, it reads only new data.
5.4.D - Interface for HMI Historical and Alarm Logs
Cimplicity’s historian and alarm logging use SQL calls to the historians to log the data in Oracle.
Separate event and alarm tables are kept in the database schema.
5.4.E - Table Structure
The table structure is ‘long and narrow’, usually having only point tag, timestamp, value, and
engineering units.
5.4.F - Query Structure (Section to be completed)
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SECTION 6 - COMMUNICATION STANDARDS
Section 6.0 - Introduction
The goal of a properly designed communications system is to carry the information sent on it in a
quick, secure, error-free manner. To accomplish this in the Automation System, several types of
communication are used including serial data highways, radio and leased line modems, local area
networks on fiber and copper cabling, frame relay wide area network, and routered
interconnections to other networks.
Section 6.1 - Control Network LAN Design
The Control Network uses fiber optic cabling from building to building or area to area due to
distance limitations and for ground isolation. Other signals are run on the fiber as well, including
video cameras and the Information Network. The fiber runs are patched in cabinets, generally in
tunnels, which have no electronics in them (passive patch panels). Connecting a remote drop or
run to a network switch cabinet is done by patching the correct fibers together in the panel.
6.1.A - Topology
The Control Network uses a series of network switches in a logical loop, broken at a location
chosen by spanning tree protocol negotiation. If any one fiber segment or switch becomes
unusable, the spanning tree break is closed and traffic continues via that route between the
remaining members. At each switch, local devices are attached.
6.1.B - Monitoring / Management
Each device on the network is capable of reporting its status via SNMP protocol, and the
switches are addressable by http protocol, having a small web server for configuration and status
built in. The computers can to some degree be monitored by SNMP using a manufacturerspecific interface. The SNMP management capabilities have not yet been implemented, but are
planned within the year.
Computer workstation management is performed by various scripts, operating system
permissions and shells, and audit/log files. In ACS/S’, redundant power supplies and RAID
level 5 disk arrays are used to mitigate the effects of single component failures.
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Section 6.2 - Control Network WAN Design
The control network WAN has been planned as a separate set of DS0 to DS1 speed lines using
frame relay services provided by a LEC. It may also be implemented as 64K segments in the
Information Network’s DS1 frame relay network. This section will be amended when the WAN
is implemented.
6.2.A - Topology
When implemented, the topology will probably be a fully webbed configuration between plants.
EMSC may be served off of Southerly or may be served separately, depending on load
projections.
6.2.B - Frame Relay Interface
When implemented, the interface will most likely be FRADs supplied by the LEC who provides
the lines. If private cabling is used, we will use Cisco for consistency with other network
equipment.
Section 6.3 - LAN / WAN Hardware
6.3.A - Switches
The switches isolate traffic between pairs of computers to a virtual network running at full wire
speed. Computers are connected at 100Mb/s. PLCs will go no faster than 10Mb/s since they use
AUI ports. The network switches have 24 10/100base T ports and two open bays in which port
modules may be added. The switches may be managed by terminal, telnet, or http.
1. Standard: Cisco 2924M-XL-EN
6.3.B - Routers
Routers are used to connect from the Control Network to the Information Network. They are set
to allow communication only between the Oracle database servers on the two networks. The
switch performs network address translation. The ports run at 10/100Mb/s.
1. Standard: Cisco 2621
6.3.C - Media Converters and Transceivers
The cost of fiber cards for the switches, particularly single-mode cards, was considered
excessive, so fiber to twisted pair media converters are used for all connections not in the
immediate area/building. This includes switch-to-switch runs. The converters have very low
latency, on the order of 4 to 8 bits worth of time delay.
For PLCs, an external transceiver is used, either AUI to fiber ST connection or AUI to RJ-45 if
in the building with a network switch. All have at least link, receive, transmit and power lights.
1. Manufacturers:
a. Lancast
b. Cabletron
c. Unicom
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2. Model numbers: Media Converters are all Lancast Twister models with ST
connectors:
a.
100M rack card, Single Mode – 7131-16-75
b.
10M rack card, Single Mode – 7111-16-75
c.
100M stand-alone, Single Mode – 2131-16-01
d.
10M standalone, Single Mode – 2111-16-01
e.
100M rack card, Multi Mode – 7131-15-75
f.
10M rack card, Multi Mode – 7111-15-75
g.
100M stand-alone, Multi Mode – 2131-15-01
h.
0M standalone, Multi Mode – 2111-15-01
i.
Rack w/dual power supplies – 7500-17HS-2A
j.
SNMP card for rack – 7501-M
3. Model numbers: Transceivers, AUI port to designated media.
a.
Single Mode fiber – Cabletron FOT-3
b.
Multi Mode fiber – Cabletron FOT-24
c.
RJ45 (twisted Pair) – Unicom ETP-20028T-S or equal from Cabletron or
Lancast
Section 6.4 - TCP / IP Protocol
The TCP/IP protocol is exclusively used for communications between PLCs, computers, and
other network devices. A numbering and naming system has been devised and implemented in
the plants.
6.4.A - Numbering system and ranges
The control network uses a private address range, 192.168.x.x. The plants use a 2-bit submask in
the third octet, 255.255.252.0, yielding over 700 addresses per subnet. The subnet scheme also
allows for devices to be changed to a 1-bit subnet and see all traffic at all plants when a wide
area network is installed. Ranges are as shown in Appendix ___, which includes a current
address list.
It must be noted that despite Allen-Bradley literature leading the user to believe PLCs can be
subnetted freely, the only subnet they will recognize is a fourth octet subnet. Because of this, all
ACS/S (HMI servers) must use the same third octet number as the PLCs. ACS (view stations)
can use any number in the subnet range. This limits the total number of PLCs and ACS/S’ to
254. We currently use less than 50% of the addresses and do not anticipate running out.
Section 6.5 - Pump Station Communication
The pump stations use leased lines and leased line modems for communication between AllenBradley PLCs. The PLC at the plant is polled to obtain the statuses and values of points at the
pump station. Note that cellular communications are being designed for new and retrofit
projects. Contact the District Manager of Process Control and Automation for the latest
standards.
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6.5.A - Modem
Two different types of modem are used, a 2-wire leased line and a 4-wire leased line modem,
both running at 33.6Kbaud or as negotiated when line conditions change.
1. Standards:
a.
4-wire leased line –
b.
2-wire leased line –
6.5.B - Dedicated Leased Lines
Dedicated leased lines are provided by the LEC, AT&T. Records for the leased lines are kept by
the EIS department.
Section 6.6 - Remote Collection System Site Modem Communication
The remote collection system sites are currently managed by a combination of Modicon PLC
software, Factorylink OS/2 software, DB/2 database, and custom software. Leased line modems
are used. The system is slated for upgrade in the next 2 years. Standards may be different
because of the need to continue operation during communications failures common with remote
sites such as these.
See the District Manager of Process Control and Automation for the latest configuration.
Section 6.7 - Remote Collection System Site Radio Communication
The remote collection system sites are currently managed by a combination of Modicon PLC
software, Factorylink OS/2 software, DB/2 database, and custom software. The radio
communication uses 924MHz MDS 9600 baud modems and currently has a 5-minute poll cycle
to allow for incomplete transmissions and other communications errors. The system is slated for
upgrade in the next 2 years. Standards may be different because of the need to continue
operation during communications failures common with remote sites such as these.
See the District Manager of Process Control and Automation for the latest configuration.
Section 7 - Electrical Standards
Section - 7.0 - See NEORSD Engineering and Construction Department
Electrical standards have been removed from the NEORSD Automation Standards and
Conventions Manual. They are now being maintained separately.
Contact the NEORSD Engineering and Construction department for the latest Electrical
Standards.
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Section 8 - CCTV System
Section - 8.0 - Introduction
Section – 8.1 - CCTV Equipment
This section provides the detailed requirements for the CCTV monitoring system.
The CCTV monitoring system details include the following:
A. Cameras
B. Camera Housing
C. Pan and Tilt Drive
D. Camera Mounting Brackets
E. Receiver
F. Surge Protection
G. Cables
H. Video Camera Transceiver Links
I. System Controller
J. Monitors
K. Digital Multiplexers
L. VCR
Detailed Specifications
8.1.A - Color Cameras:
1. Cameras for the CCTV Monitoring System shall be digitally encoded to enable a
variety of picture enhancements. The digital cameras shall provide increased lens
sensitivity, aperture correction, electronic light control (equivalent to shutter speed of
1/60 sec. and 1/15,700 sec.), and back lighted compensation for crisp, sharp pictures.
The cameras shall be equipped with a zoom auto 2 inch iris lens for wide angle
viewing, with a maximum aperture ratio of 1:0.75 and a filter size of M40.5 mm.
Each camera shall be provided with pan/tilt/zoom features for motion control.
2. All cameras shall permit program setup of camera ID, light control, backlight
compensation, shutter speed, and automatic gain control.
All programmed
information shall be retained in each camera's non-volatile memory. A setup disable
function shall prevent accidental and unauthorized operation of the camera system.
The lenses shall be one (1) inch nominal motorized zoom.
3. The Camera pick-up device shall be 512(H) x 492(H) pixels, minimum, Interline
Transfer CCD.
4. The cameras shall consist of the following features
a. Scanning Area:Scanning Area shall be 4.8(H) x 3.6(V) mm.
b. Scanning System: 525 lines/60 fields/30 frames,
Horizontal 15.734 kHz,
Vertical 59.94kHz.
c. Video Output: 1.0 V p-p, composite, 75 Ohms,BNC Connector
d. Minimum Illumination:0.11 fc at f/1.2
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e. Detail:
User selectable, Sharp or Soft
f. Temperature:
-10 deg C to 50 deg C
g. Humidity:
0 to 90 % RH, Non-condensing
h. Power Requirements:
0.2 amps at 120 VAC, 60 Hz, single phase.
i. Mounting:
Suitable for outdoor or Indoor mounting.
5. Product and Manufacturer: Provide one of the following:
a. Panasonic
b. Or equal
8.1.B - Camera Housing:
1. Camera housings shall be rated for indoor, environmental and explosion-proof
applications, as required.
2. For indoor applications, each camera shall be enclosed in an extruded aluminum
housing. Housing shall include a removable front cap to access lens focus adjustment
and servicing, and a rear cap for access to camera sled and installation of power and
video cables. The housing shall be compatible for use with ceiling, column, pedestal,
pipe, or wall mount brackets.
3. For environmental applications each camera shall be enclosed in a weatherproof
extruded aluminum housing with thermostat controlled, factory installed heater and
blower, both at 24 vac. The housing shall include a side hinge to access lens focus
adjustment and servicing and shall be suitable for use with a sun shield. The housing
shall be compatible for use with ceiling, column, parapet, pedestal, pipe, pole, or wall
mount brackets.
4. Explosion-proof housings shall be provided for cameras located in hazardous
locations as designated in the camera list. The housings shall comply with the
requirements for Class 1, Division 1, Group D, Hazardous locations as defined by the
National Electric Code, the requirements of Underwriters Laboratories Standard, U.L.
1203, and all other safety codes pertaining thereto.
5. The camera housings shall consist of the following features:
a. Extruded aluminum body.
b. Camera access through rear cap.
c. Unit base bolt hole pattern to be compatible with remote positioning device
provided.
d. Plastic end caps
e. Sunshield for outdoor locations
6. Product and Manufacturer: Provide one of the following:
a. PELCO
b. Or equal.
8.1.C - Pan and Tilt Drive:
1. All cameras shall be provided with remote positioning devices consisting of pan and
tilt drives.
2. Pan and tilt drives for environmental cameras shall be of weatherproof, corrosion
resistant construction.
3. Pan and tilt drives for cameras in hazardous locations shall be enclosed in explosionproof housings. The housings shall comply with the requirements for Class 1,
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Division 1, Group D, Hazardous locations as defined by the National Electric Code,
the requirements of Underwriters Laboratories Standard, U.L. 1203, and all other
safety codes pertaining thereto.
4. As a minimum, the pan and tilt drives shall consist of the following features:
a. Panning Angle:
10 - 340 degrees (Adjustable).
b. Tilting Angle:
45 degrees up, 45 degrees down from
center position for indoor cameras.
15 degrees up, 60 degrees down from center
position for outdoor cameras.
c. Panning:
Automatic or Manual (Selectable)
d. Panning speed:
7 degrees/sec.
e. Tilting Speed:
4 - 45 degrees/sec.
f. Operating Temp:
-4 deg F to 122 deg F.
g. Power Supply:
24 VAC (Environmental).
120 VAC (Explosion-proof)
h. Capable of inverted operation.
i. Externally adjustable limit switches.
j. Pan and tilt drives with internal stops.
k. Tilt motor thermal protection switch.
l. Pan motor impedance protection.
5. Product and Manufacturer: Provide one of the following:
a. PELCO
b. Or equal.
8.1.D - Camera Mounting Brackets:
1. All mounting brackets shall be of corrosion-resistant construction and shall be load
rated to support camera, housing and pan and tilt drive components and accessories
specified herein. Mounting heads shall be adjustable.
2. Mounting shall be suitable for ceiling, column, parapet, pedestal, pipe, pole, or wall
mounting, as indicated in the camera list and mounting details provided in this
specification.
8.1.E - Receiver:
1. Receivers shall be provided to relay control signals to the camera pan/tilt units,
cameras and accessories specified herein. All mounting hardware shall be provided
for complete installation.
2. For environmental cameras, receivers shall be installed in weatherproof enclosures.
For cameras located in hazardous areas, receivers shall be enclosed in explosionproof housings. The housings shall comply with the requirements for Class 1, Group
D, Hazardous locations as defined by the National Electric Code, the requirements of
Underwriters Laboratories Standard, U.L. 1203, and all other safety codes pertaining
thereto.
3. Product and Manufacturer: Provide one of the following:
a. American Dynamic.
b. Or equal.
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8.1.F - Surge Protection:
1. Each camera shall be protected with lightning arrestor at each end of the cable, at the
camera site and the head end equipment at the control console. The connections to
the surge protection devices shall be made with BNC connectors.
2. Product and Manufacturer: Provide one of the following:
a. Atlantic Scientific.
b. Or equal.
8.1.G - Cables:
1. Provide coaxial cables with connectors at both ends for interconnection of supplied
equipment at the control console.
8.1.H - Video Camera Transceiver Links:
1. The cameras shall be connected to the central monitoring equipment via Fiber Optic
Links for transmission of baseband video signals over long distances, without
repeaters and no user adjustment. The transmitted signal shall be immune to EMI and
RFI interferences. The transceivers shall transmit video and provide bi-directional
control for pan/tilt/zoom functions.
2. The transceiver links shall consist of the following:
a. Video Bandwidth:
6.5 MHz
b. Optical Loss:
up to 13 dB, maximum over the entire
range.
c. Wavelength:
1300 nm.
d. Transmitter Power:
-15.5 dBm.
e. Receiver Sensitivity:
-28.5 dBm.
f. Input level:
1.0 V p-p
g. Input Impedance:
75 Ohms.
h. SNR:
> 50 dB
i. Differential Phase:
2 degree maximum
j. Differential gain:
3% maximum.
k. Connectors:
BNC
l. Power Supply:
320 mA at 12 to 18 VDC for both
transmitter receivers.
m. Fiber Cable:
62.5/125 um fiber at 25 degree
3. Product and Manufacturer:
Provide one of the following:
a. Litton Poly Scientific.
b. Or equal.
8.1.I - System Controller:
1. The microprocessor based multifunction system controller shall be used for setup ,
camera control, and video routing. Two (2) lines of LCD display, four (4) Function
keys, numeric keypad, joystick, camera key and monitor key, and cursor keys shall
be provided.
2. Sequence function shall include go, stop, back sequence, forward sequence,
increment and decrement sequence. Lens functions shall include iris open, close,
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focus far, near, zoom telephoto and wide angle. Joystick functions shall include tilt
up and down, pan right and left and preset.
3. The controller shall communicate with the multiplexer via RS-485 port at 9600 baud,
minimum.
4. The system controller shall contain the following minimum features:
a. Menu driven program for camera, video routing setup for up to 128 cameras
and 16 monitors.
b. Permit programming of group of cameras for display on group of monitors.
c. Password protection against use by unauthorized personnel.
d. LED alarm indication blinking to identify an alarm conditions exists.
e. LCD display of date, time, camera number, alarm status, and 16 character user
programmable titles for immediate location identification.
f. The keyboard shall be capable of activating and controlling all control
functions described above for each camera, with a joystick and Function
Keys.
g. All custom configuration programs, camera settings, I/O tables, etc. shall be
made available to the NEORSD.
h. The Controller shall interface with a 80 column parallel printer for hard copy
printouts of alarms. Each alarm shall be date and time stamped.
5. Product and Manufacturer: Provide one of the following:
a. Panasonic.
b. Or equal.
8.1.J - Monitors:
1. The color video monitor shall be 14-inch diagonal screen monitor with horizontal
resolution of at least 700 lines center. The monitors shall feature manual controls for
adjustment of tint, sub-tint, brightness, sub-brightness, contrast, sub-contrast, picture
and audio level. The monitors shall have 2 BNC video outputs and 2 BNC video
inputs, S-video input and output connectors The monitors shall be UL listed.
2. The monitors shall consist of the following features:
a. Video Input:
Two (2) 1.0 V p-p, 75 Ohm, composite via a
BNC connector.
b. Video output:
Two (2) 1.0 V p-p, 75 Ohm, composite via a
BNC connector.
c. S-Video Input: One (1) Y: 1.0 V p-p, 75 Ohm, C: 0.286 V p-p
75 Ohm, via mini DIN 4-pin connector.
d. S-Video Output: One (1) Y: 1.0 V p-p, 75 Ohm, C: 0.286 V p-p
75 Ohm, via mini DIN 4-pin connector.
e. Audio Input:
Two (2) -8 dB/Hi-Z via RCA connector
f. Audio Output: Two (2) RCA connecters
g. Power Supply: 120 VAC, 60 Hz, single phase.
3. Product and Manufacturer: Provide one of the following:
a. Panasonic.
b. Or equal.
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8.1.K - Digital Multiplexers:
1. The digital multiplexer shall be high performance, flexible and shall control up to 16
video input channels and permit multiplexed field recording of 16 cameras with a
single VCR. The unit shall permit full screen monitoring of 4,7,9,10,13 and 16 multi
screen monitoring modes.
2. The multiplexer shall include front panel and remotely controlled VTR functions
including record, play, reverse play, rewind, forward, pause, stop and recording time
mode. Up to 4 multiplexers may be cascaded to record up to 64 cameras inputs. The
single spot controller shall display video images of any camera connected to the
system via system controller. The unit shall provide a digital display on the monitor
and also recording of year, month, day, hour, minute and second as well as
alphanumeric camera location ID up to 8 characters, on tape.
3. The multiplexer shall feature a built-in programmable switcher with dwell time and
camera order programming. It shall automatically switch camera images to enable
sequential spot monitoring and simultaneous field recording. All multiplexers
provided under this Contract shall be connected via RG59/U coaxial cable using BNC
connecters.
4. The multiplexer shall allow for recorded images to be played back in full screen, or in
4, 9 or 16 multi screen display mode. It shall also feature multi spot playback mode
which shall combine 3 multiplexer functions, playback, record, and live multi-screen
monitoring. In this mode, the unit shall feature playback from video tape recorder #1,
displayed in the upper left corner display of 4, 7, 10, 13 multi screen modes. In
addition, the duplex multiplexer shall feature live viewing of cameras on remaining
multi screen views. Freeze mode shall be available for VCR playback
5. The multiplexer shall provide access to all camera control, setup, alarm functions,
including preset sort and sequence, Super Dynamic activation, digital motion mask
set, electronic sensitivity up and backlight compensation set-up.
6. The controls for pan/tilt/zoom cameras shall be accessible via system controller.
These functions shall include direct access of preset position, zoom near or far, focus
near or far, iris open or close, pan right or left, tilt up or down. The multiplexer shall
also provide 1/60 sec refresh rate for 4 cameras at once. Loss of video detection for
any channel shall be alarmed.
7. In addition to monitor displays and alarms, the tape recording shall be date and time
stamped for all channels.
8. Cameras setup and control functions shall be accessible for cameras 5-8, 9-12, and
13-16, which shall provide cable compensation of up to 3000 feet with no loss of
video or control signal degradation.
9. The following features shall be provided as a minim
a. Resolution:
720 x 486 pixels, minimum.
b. Frame memory:
Quantizing 8-bit.
c. Internal Sync:
2:1 Interlace, Horizontal 15.734 kHz, Vertical
9.94 kHz.
d. Input Signal:
Sixteen (16) 1 V p-p / 75 Ohm (BNC)
connector with loop through outputs, and
automatic termination.
e. Spot Input:
1 V p-p / 75 Ohm (BNC) x 1
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f. Time Adjust
Input:
g. Output Signal:
1 D-SUB 37 pin Connector
Spot Input: 1 V p-p / 75 Ohm (BNC) x 1.
Multi screen Output: 1 V p-p /75 Ohm (BNC)
x 1, S.Video x 1.
Recording Output: 1 V p-p/75 Ohm
(BNC) x 1, S.Video x 1.
h. Power Supply:
120 VAC, 60 Hz, single phase.
10. Product and Manufacturer: Provide one of the following:
a. Panasonic.
b. Or equal.
8.1.L - Video Cassette Recorder (VCR):
1. The VCRs supplied under this contract shall be industrial grade recorder and not a
modified consumer unit. The recorder shall be VHS compatible. The VCRs shall
have two (2) audio channels and flying erase heads for cleaning transitions. The
recorders shall include both SP and SLP record mode and SP, LP, and SLP play back
modes. All connections shall be BNC or RCA connectors. Video image processor
shall multiplex up to 16 video signals and output to a VCR for recording on one tape
simultaneously without synchronization between inputs. Each camera recorded on
the VCR tape shall be numbered and shall be played back as a single display or quad
display by selection of any channel on the video image processor.
2. A freeze switch shall allow study of a single picture. The unit shall be capable of 19
inch rack mounting.
3. The following features shall be provided as a minimum:
a. Modulation System:
Luminance, FM azimuth recording.
b. Tape format:
VHS tape
c. Tape Speed:
33.35 mm/sec
d. Recording/ playback:
12/8/24 hours in linear slow Time Mode
and 24 / 48 / 72 / 84 / 120 / 180 /
40 / 480 hours and 1-shot in time lapse
mode.
e. FF/Rewind speed:
3 minutes, approx.
f. Video IN (BNC)
1.0 V p-p, 75 ohm unbalanced
g. Video Out (BNC)
1.0 V p-p, 75 ohm unbalanced
h. SNR:
VHS 46 dB
i. Horizontal Resolution: VHS 240 lines in color
j. Audio IN Phono
-10 dBV, 47 ohms, unbalanced
k. MIC In:
-60 dBV, 600 ohms to 4.7 kOhms,
unbalanced
l. Camera Switch Output
Timing 1: 5V/0V, Pulse width: 4.7 msec
Timing 2: 12V/0V, Pulse width:16.7 msec
m. Power Supply:
120 VAC, 60 Hz, single phase.
4. Product and Manufacturer: Provide one of the following:
a. Panasonic.
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b. Or equal.
Reference Standards
1. American National Standards Institute (ANSI).
2. Factory Mutual (FM).
3. Institute of Electrical and Electronic Engineers (IEEE).
4. National Electric Code (NEC).
5. National Electrical Manufacturers Association (NEMA).
6. Underwriters' Laboratories (UL).
Installation Details - this section does not contain all installation details for the
equipment/ system shown, only those that are required by the NEORSD. These details
may exceed those required by the equipment manufacturer or local codes.
1. Install in conformance with the requirements of NEC.
2. Install the video cameras at the locations shown on the drawings and in accordance
with the manufacturer's recommendations.
3. CONTRACTOR shall ensure that adequate strain relief is provided in the installation
of cameras to prevent premature damage to cables caused by continual flexing in
pan/tilt applications.
SECION 9 - Instrumentation, System Integration, and Testing
Section 9.0 - Introduction
This section reviews the standards and conventions for instrumentation, panels, system
integrators, and testing.
Section 9.1 - Instrument and Panel Tagging
Instrument and control valve tags shall be the NEORSD site designator followed by the
NEORSD area number/location followed by the ISA (International Society of Automation)
designation and the instrument loop number. All alpha characters are upper case. Components
of the tag are separated by dashes.
Wastewater Treatment Plant Instrument and Control Valve Tag Format:
S-AA-Z...Z-nnnn
Where:
“S”
is the site designator (upper case). “E” for Easterly. “W” for Westerly. “S” for
Southerly. [Collection System sites are listed in Part II, Section 1.5, Paragraph I Site Designator.]
“AA” is a two digit numeric code designating the process area in a treatment plant (see
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tables below for treatment plant process area codes)
“Z...Z” is the ISA alpha character designation for the instrument or control valve
function (follows the ISA standard “ISA-5.1” entitled “Instrumentation Symbols
and Identification”). It is typically between 2 and 4 characters long, upper case.
“nnnn” is the same four-digit loop number identifier to be used in the point tag as
described in Section 1.5 - Point Tag Naming Convention.
For example, at the Southerly Wastewater Treatment Center (WWTC), a flow indicating
transmitter in the Second Stage Aeration Area would have the tag:
S-22-FIT-nnnn
A high level switch in the Screening Area at the Easterly WWTP would have the tag:
E-05-LSH-nnnn
A level control valve at the Westerly WWTP Disinfection Area would have the tag:
W-35-LCV-nnnn
Note to specifier: P&IDs typically do not show the entire instrument and valve tag as long as
there is a note on the P&ID that all instrument and valve tags are preceded by the site designation
and area number, for example, “S-22”. The instrument and valve “bubble” on the P&ID would
contain, for example, “FIT-1005”.
Collection System Instrument and Control Valve Tag Format:
S-LL-Z..Z-nnnn
Where:
“S” is the Collection System site type designator (upper case alpha). “P” is used for
remote pump stations and “A” is for automated regulator sites. Other Collection
System site abbreviations are listed in Part II, Section 1.5, Paragraph I – Site
Designator.
“LL” is a two character upper case alpha code designating the location in the Collection
System. See Part II, Section 1.5, Paragraph II – Collection System and Remote
Sites for the codes.
“Z...Z” is the ISA alpha character designation for the instrument’s function (follows the
ISA standard “ISA-5.1” entitled “Instrumentation Symbols and Identification”).
It is typically between 2 and 4 characters long, upper case.
“nnnn” is the same four-digit loop number identifier to be used in the point tag as
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described in Section 1.5 - Point Tag Naming Convention.
A level indicating transmitter at the Division Avenue remote pump station would be:
P-DA-LIT-nnnn (where “P” is for remote pump station, “DA” is for the Division Avenue Pump
Station, “LIT” is for level indicating transmitter, and “nnnn” is for the loop number. [Note that
there are no process area numbers used in the Collection System]).
Note to specifier: P&IDs typically do not show the entire instrument and valve tag as long as
there is a note on the P&ID that all instrument and valve tags are preceded by the site type
designation and location, for example, “P-DA”. The instrument and valve “bubble” on the P&ID
would contain, for example, “LIT-1006”.
Panel tags shall follow the formats listed below. Examples of panels are PLC control panel
(PLC), local control panel (LCO), local control station (LCS), motor control center (MCC),
variable frequency drive (VFD) panel, area control panel (ACP), operator interface terminal
(OIT), etc.
Wastewater Treatment Plant Panel Tag Format:
S-AA-P..P-N..N
Where:
“S” is the site designator (upper case alpha). “E” is for Easterly. “W” for Westerly.
“S” for Southerly.
“AA” is a two digit numeric code designating the process area in a treatment plant See
tables below for numeric codes for plant areas)
“P. .P” is the abbreviation (upper case alpha characters) for the type of panel or device.
Examples are: PLC, RIO, LCP, LCS, MCC, VFD, OIT, HMI. See panel
abbreviation list in Part IV, Section 7.1.
“N..N” is the identifier for the PLC, OIT, MCC, etc. Examples are: CN, CS1, CS2,
COL1, COL8A, RSP1, BL1.
Sample treatment plant panel tags:
S-19-PLC-CS, S-20-PLC-CN, S-19-RIO-CS1, S-19-OIT-CS1, S-19-OIT-CS2, S-20PLC-BL1, S-20-PLC-BL2.
Collection System Panel Tag Format:
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S-L.L-P..P-N..N
Where:
“S” is the Collection System site type designator (upper case). “P” is used for remote
pump stations and “A” is for automated regulator sites. Other Collection System site
abbreviations are listed in Part II, Section 1.5, Paragraph I – Site Designator.
“LL” is a two or three character upper case alpha code designating the location in the
Collection System. One example is “DA” for the Division Avenue pump station.
See Part II, Section 1.5, Paragraph II – Collection System and Remote Sites for the
codes
“P. .P” is the abbreviation (upper case alpha characters) for the type of panel or device.
Examples are: PLC, RIO, LCP, LCS, MCC, VFD, OIT, HMI. See panel
abbreviation list in Part IV, Section 7.1.
“N..N” is the identifier for the PLC, OIT, MCC, etc.
Below are process area codes (“AA” in instrument, control valve, and panel tag format) for the
wastewater treatment plants: the Westerly Wastewater Treatment Center, the Easterly
Wastewater Treatment Plant and the Southerly Wastewater Treatment Center.
The process area codes below were updated in December 2012. Changes to the codes and
descriptions after this date and before the next revision of the Plant Automation Standards
Manual can be found in the District’s Oracle Work and Asset Management system (WAM-SPL).
9.1.A - Westerly Wastewater Treatment Center
Westerly Wastewater Treatment Center
Area Description
Administration Building
Switchgear Building
Screen Building
CSOTF Dewatering Building
Pipe Gallery Area (Plant-wide)
Primary Settling Tanks Area
CSOTF Degritting Building
Solids Handling Building
Inactive (Formerly Lube Storage Building)
Gravity Thickener Tank Area
Chemical Handling Building
Disinfection Area
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11
12
13
14
15
16
20
21
25
30
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Maintenance Center
Emergency Backup Generators
Hypo / Bisulfite Building
CSOTF Settling Basins Area
Final Settling Tanks Area
Trickling Filters Area
Solids Contact Tanks Area
Primary Effluent Pump Station
Blower Room (Solids Contact Area)
Return Secondary Sludge Building
RSS Pumps / Odor Control Building
MCC Room TF / SC Complex
Substation 9 TF / SC Complex
Locker / Storage Building
Inactive (Formerly Stockroom Building)
Machine Shop Area
Fuel Oil Storage Area
Gas Meter House Building
Security Building
Inactive (Formerly Permanent Office Trailers)
General Plant Area
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40
70
75
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
96
97
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9.1.B - Easterly Wastewater Treatment Center
Easterly Wastewater Treatment Plant
Area Description
Inactive (Retired)
Inactive (Retired)
Screening Area
Screening Conveyance Area
Detritus Tanks Area
Grit Dewatering Area
Collinwood Pump Area
Headworks Main Control Area
Headworks Building – Lower Level
Headworks Building – Upper Level
Engineer Building / Lube Shop
Pre-Aeration Tanks Area - demolished
Aerated Grit Facility
Grease Flock Area
Grease Reactor Area
Chemical Storage and Feed Facility
Service Building West Gallery
Service Building Central Gallery
Service Building East Gallery
Service Building Central Gallery - Basement Area
Primary Settling Tanks Area
Primary Main Control Room Area
Southerly Pump Building Complex
Service Building Area
Lake Water Pump Building
Lubrication Storage Building (Rev. F)
Wet Weather Pump Station Area
Aeration Tanks Area
Pump Building West Gallery
Pump Building East Gallery
Pump Building Control Area
Pump Building 2nd Level Central Area
Pump Building Basement Area
Pump Building Area
Disinfection - Bypass Building
Final Settling Tanks Area
1st Floor Blower Room Area
2nd Floor Blower Building Area
Blower Building Area
Emergency Backup Generators
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01
02
05
06
07
08
09
10
11
14
15
18
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
38
39
40
41
42
43
45
46
48
50
51
54
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Screw Pump Area
Easterly
Wastewater
(continued)
Treatment
Area Description
Effluent - Main Control Office
Bisulfite Pump and Storage Area
Inactive (Retired)
Effluent - 2nd Level Basement Area
Effluent - 3rd Level Basement Area
Chlorine Contact Tanks Area
Effluent - Monitoring Room Area
Effluent Building Area
Administration Building
Tunnel – Administration to Blower Building Area
Tunnel - Administration to Service Tunnel Area
Tunnel – Blower to Pump Building Area
Tunnel - Pump to Service Building Area
Stockroom Area
Machine Shop Area
Security Building Area
General Plant Area
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Plant
Code
68
69
70
71
72
73
74
78
80
84
85
86
87
91
92
96
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9.1.C - Southerly Wastewater Treatment Center
Southerly Wastewater Treatment Center
Area Description
Gas Well
Screen & Grit Building
Access Building #1
Access Building #2
Access Building #3
Access Building #4
Access Building #5
Primary Settling #1-10 Area
Primary Setting #11-18 Area
Chemical Handling Building
First Stage Aeration "A" Area (Not In Service)
First Stage Aeration "B" Area (Not In Service)
First Stage Aeration "C" Area
First Stage Blower Building
First Stage Settling "A" Area (Not In Service)
First Stage Settling "B" Area (Not In Service)
First Stage Settling "C" Area
Return Sludge Pump Station “C” Gallery
Second Stage Lift Station Building
Second Stage Aeration Area
Second Stage Blower Building
Second Stage Settling Area
Second Stage Return Sludge Pumping Station
Effluent Filter & Administration Building
Operators Locker Room
Disinfection Building
Cyclone Degritting Building
Gravity Thickeners Building
Excess Activated Sludge (EAS) Thickening
Building
Sludge Storage Tanks Area
VCU & Thermal Conditioning
T.C. Sludge Thickeners Building
T.C.S.T. Odor Control Building
Sludge Dewatering Building
Dewatering VCU Building
Incineration Building
Incineration - Auxiliary Building
Ash Lagoon Area
Future Fluid Bed Incineration (FBI)
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00
01
02
03
04
05
06
07
10
11
12
13
14
15
17
18
19
20
21
22
23
24
26
30
33
34
35
36
37
38
39
40
41
42
43
44
45
46
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Skimmings Building #1
48
Southerly Wastewater Treatment Center
(continued)
Area Description
Code
Skimmings Building #2
50
Skimmings Decant & Storage
51
Steam Generation Building
52
Odor Control B Building
53
Waste Liquor Handling Building
54
Odor Control A Building
55
Digester A (Not In Service)
56
Future Biosolids Handling (FBI project)
57
CVI Lift Station Building
58
Stormwater Pump Station #1
60
Stormwater Pump Station #2
61
Stormwater Pump Station #3
62
River Gates Area
63
Future Green Energy Building (FBI project)
67
Emergency Backup Generators & Switchgear Bldg
70
Main Substation
73
Equipment Storage Building
75
Old Pump House
86
Easterly Sludge Line Vault Area
87
Labor Storage Building
88
Building Maintenance / Scour Bldg
89
Inactive (Retired)
91
Water Meter House #1 & #2
93
Gas Meter House
94
Maintenance Building
95
Security Building
96
Resident Engineering Building
97
General Plant Area
99
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Section 9.2 - System Integrator
9.2.A - Summary
All equipment, components, and materials required for the control system, network, and other
items within scope shall be furnished by the System Integrator who shall assume the responsibility for suitability and performance of all items. New panels and the equipment inside those
panels shall be furnished and mounted by the System Integrator. All wiring within the panel
shall be provided by the System Integrator. Equipment for existing panels shall be provided and
installed by the System Integrator. Installation of the panels and mounting hardware and the
procurement and installation of all interconnecting wire, cable, conduit, and cable tray (as
required) shall be the responsibility of the CONTRACTOR. The CONTRACTOR shall also
provide and install all power and other services required by the panels.
It shall be the responsibility of the CONTRACTOR to insure that the System Integrator is
performing required duties and providing required drawings, documentation, and data.
9.2.B - System Integrator’s Qualifications
Shall have a demonstrated record of prompt positive response to field failures.
Shall have a record of prompt deliveries in accordance with contract obligations required for
previous projects
Shall have a demonstrated experience record of successful installations for a minimum of three
years.
Shall be a member in good standing of the Control System Integrators Association (CSIA) or
endorsed by other industry organizations. Certified members of CSIA preferred. System
Integrator must provide proof of successful completion of previous projects and shall be subject
to one or more audits, at the OWNER’s discretion, before, during, or after the project. System
Integrator shall supply examples of and references from at least three similar projects involving
DeviceNet within the past five years that they have successfully completed.
For all Rockwell and Rockwell partner equipment, the System Integrator shall be a Rockwell
listed and certified Solution Provider. Secondary preference shall be given to Rockwell listed
System Integrators.
System Integrator shall have an office or location staffed with competent System Integrators that
shall be used for the Work within 250 miles of the job site.
System Integrator shall have ISO 9001 certification. If System Integrator does not have this
certification, then they shall be subject to a quality management audit by the District or the
District’s representative.
The System Integrator shall supply detailed resumes and work experience for the staff that shall
be working on the project. This requirement shall apply both to office staff and field staff of the
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System Integrator. Because of the highly technical and skilled nature of the work, the District
shall retain the right of approval and removal of all System Integrator staff.
9.2.C - System Integration Responsibilities
CONTRACTOR shall retain the System Integrator to assume the responsibilities specified
below. However, delegating these specified responsibilities to the System Integrator shall not
relieve the CONTRACTOR of the ultimate responsibility for completion of the work specified in
the Contract.
The Integrator shall:
•
Install and wire the system
•
Verify signal paths for all points connected to the control system under the Contract,
whether new or existing
•
Verify that termination points have been properly wired
•
Develop detailed documentation that covers system configuration, control logic
programming, HMI system programming, loop checks, testing, troubleshooting,
commissioning of the instrumentation / control system in accordance with the Contract
Documents, network and system interconnection drawings, and verification of meeting
all applicable codes, standards, and regulations
•
Provide all specified process control system related training.
The Integrator shall also be responsible for:
•
Integration of system workshops, installation, testing, and commissioning activities into
the overall project schedule
•
Preparation, organization, binding, electronic copying, submission, and correction of all
instrumentation and control system submittals
Where requested by the District or its representative, the Integrator shall submit documents
pertaining to standards, engineering practices and recommendations, and physical systems and
equipment that support:
•
The validity of analytical/mathematical expressions that will be programmed into the
process control and automation system.
•
Development of written testing and verification procedures for every aspect of system
performance.
•
Installation, integration, and configuration of all software components and development
of custom software, as required.
•
Integration and interfacing of the instrumentation and control system hardware, software,
licenses.
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9.2.D - System Integrator’s Project Personnel
CONTRACTOR shall require the System Integrator to provide a Field Engineer with the
following responsibilities.
Provide advice and technical consultation concerning installation techniques and procedures for
equipment furnished. The Field Engineer shall be on-site during the installation phase as
required.
Installed system integration, customization, checkout, calibration, adjustment, and startup
Provide maintenance services during the field test.
Resolving problems encountered during initial startup and testing of all instrumentation and
control equipment.
The Field Engineer shall have a minimum of five years experience in systems engineering and
startup and shall have a thorough working knowledge of the hardware and software supplied for
the instrumentation and control system.
9.2.E - Factory Acceptance Testing
If any type of process controls are to be provided, or expansion or modifications to the existing
process control system are required to accomplish the objectives of a project, the Contractor
must be required to perform, a factory acceptance test (FAT). The intent of the FAT is to
demonstrate that the control panels, processors, controller(s), I/O, and HMI and OIT hardware
and software and all other system components and software are demonstrated and verified for
conformity with the contract requirements, approved submittals, and workshop discussions. The
most recent version of the Component Settings Record (See Section 9.2S) shall be available and
updated as necessary throughout the FAT. Operation of field devices shall be simulated either
with hardware (switches, lights, potentiometers, etc.) or software as approved by the District.
Software simulation routines that reside in the program of the equipment being tested shall be
implemented in a manner that makes the routines easily identifiable and completely removable
from the program prior to the site commissioning without affecting the MCS functionality of the
program. The factory acceptance test shall demonstrate the following:
• Responses to all inputs
• Operation of all outputs with a dummy load
• Loop operation
• Control sequences
• Software and hardware Interlock operation
• Functionality of all communication links, including Ethernet, Fieldbus, DeviceNet,
ControlNet, Data Highway, and similar communications
• Network communications
• HMI and OIT screens, displays, and alarms
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• Operator control functions
• Physical, password, and information security measures
• Historized data
During the performance of the FAT, all HMI and OIT graphical screens shall be verified for
completeness, functionality, and responsiveness. Also, all I/O shall be verified for proper linking
to HMI and OIT graphical screen objects/symbols, alarm and event logs, and recording in the
Historian. This shall be documented on I/O Checkout certification sheets that are described in
Part II, Section 9.2R. Test all PLC I/O module channels using physical/hardwired connected test
equipment that generates the signal type and span appropriate for each configured I/O module
channel. Test all networked I/O using the actual networked equipment using physical/hardwired
connected test equipment that generates the signal type and span appropriate for the configured
networked equipment. Use of simulated I/O in the FAT shall be minimized and be allowed only
with concurrence of the District.
Revisions to the PLC, OIT, and HMI software programming, from the start to the conclusion of
the FAT, shall be continuously tracked using the Rockwell Software FactoryTalk AssetCentre
application. Backup copies of all programs shall be made at the conclusion of the FAT.
Control panels that incorporate only hardwired control circuits shall undergo shop testing at the
panel building facility, similar to a FAT, to demonstrate and verify proper functionality of the
control panel.
The Contractor shall be required to provide the following documentation pertaining to the FAT:
•
FAT Plan that describes the logistics and administrative aspects of the FAT
•
List of all project deliverable panels, and control system equipment that will be
demonstrated in the FAT
•
List of all ancillary test equipment/apparatus used in the FAT
•
Project documentation associated with the project deliverables
•
FAT test procedures that precisely describe the features and functionalities to be
demonstrated and the activities used to prosecute the demonstration
•
FAT test records documenting and attesting to the FAT results.
9.2.F - System Checkout, Startup, and Commissioning Responsibilities
CONTRACTOR shall be responsible for providing all labor, materials, equipment, and
incidentals necessary to perform and coordinate the checkout, startup, field testing, and
commissioning of the instrumentation and control system.
CONTRACTOR shall retain the services of the System Integrator to supervise and/or perform
checkout and startup of all system components. As part of these services, the System Integrator
shall include for those equipment items not manufactured by him the services of an authorized
manufacturer’s representative to check the equipment installation and place the equipment in
operation. The manufacturer’s representative shall be thoroughly knowledgeable about the
installation, operation, and maintenance of the equipment.
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The Contractor shall supply the District with all information required including, as the District or
its representative may request, references to engineering standards, engineering practices, and
recommendations, and physical systems and equipment that validate analytical/mathematical
expressions programmed into the process control system for the District to configure or program
equipment or control systems under the District’s responsibility. Information shall be complete
and provided when requested.
System Integrator shall develop written testing and verification procedures for every aspect of
system performance. Procedures shall include the criteria for acceptance. Procedures for
correction and retesting in case of error or failure shall be included.
All affected parties shall review these procedures and the District shall approve the
procedures prior to testing. Omissions or inadequacies in procedures do not relieve the System
Integrator from providing a complete checkout, startup, and commissioning.
System Integrator shall, with the CONTRACTOR’S assistance, perform any other checks or
testing, deemed necessary by the NEORSD ENGINEER or their representative, to demonstrate a
fully functional system (or systems) and properly operating system(s) to the satisfaction of the
NEORSD.
Tests shall be re-performed if there is a failure during all or part of a test or at the discretion of
the NEORSD ENGINEER or their representative.
9.2.G - Integrity Testing
Electrical conductors shall be tested for continuity and insulation resistance according to industry
standards and NEORSD requirements.
9.2.H - Calibration
All instrumentation, devices, and actuators shall have been calibrated and documented as such by
the manufacturer before shipment to the Owner’s site.
All instrumentation, devices, and actuators shall also be field calibrated after installation and
before commencement of checkout and startup. Calibration services shall conform to the
following requirements at a minimum:
•
All sensors, elements, indicators, transmitters, and actuators shall be calibrated
accordance with NIST-traceable standards following the manufacturer’s instructions.
•
All calibration equipment shall have current independent certification of accuracy.
•
Calibration equipment shall have measurement accuracy that is a minimum of three times
(3x) the expected accuracy of the device being calibrated.
•
Actuators shall be stroked and control action, limits, and travel switches shall be verified.
•
Each calibrated instrument shall be field-marked with a waterproof calibration tag
bearing the device identifier (asset number or P&ID tag), date of calibration, calibration
range (zero and span), units, remarks, (such as any special conditions found), trips,
alarms, or other limit settings, and initials of the technician performing the work.
•
An Instrument Certification sheet shall be completed for each instrument and included in
the system documentation. A detailed description is given in Paragraph 9.2.O.
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•
A Final Control Element Certification sheet shall be completed for each field calibrated
control valve, actuator, and damper, etc. and included in the system documentation. A
detailed description is given in Paragraph 9.2.P.
9.2.I - System Checkout and Startup
CONTRACTOR must provide the services of qualified instrumentation and control system
technicians, including, where applicable, those of System Integrator(s), instrument and control
suppliers and equipment manufacturers to perform the following:
•
Preparation of updates to all instrumentation and control documentation including, but
not limited to drawings, process control narratives, I/O list, Component Setting Record
and manuals.
•
Check and approve the installation of all instrumentation and control components and all
cable and wiring connections between the various system components prior to placing the
various processes and equipment into operation for site acceptance testing.
•
Conduct a complete system checkout and adjustment including calibration of all
instruments, check of all loops, verification of setpoints and interlocks, and testing of
final control actions.
•
Check all communication networks including, but not limited to, serial communications,
Modbus, Modbus Plus, DeviceNet, Profibus, Ethernet, ControlNet, fieldbus, etc. as
applicable. All HMI and OIT graphics shall have been verified for completeness,
functionality, and responsiveness during the FAT. During the FAT, all I/O shall be
verified for proper linking to HMI and OIT graphical objectives/symbols, alarm and
event logs, and recording in the Historian. All problems encountered shall be promptly
corrected to prevent any delays in operational testing and startup of the various unit
processes.
Field checkout, configuration, calibrations and adjustments associated with packaged process,
mechanical and electrical equipment (e.g., chlorinators, samplers, variable-speed drives,
packaged environmental and HVAC equipment and systems, fire alarm/protection systems and
security systems, etc.) that have interfaces to the process control and automation system shall be
performed by qualified, properly trained employees of the manufacturer or by manufacturerauthorized/recommended service providers. In general, standard documentation normally
produced by the manufacturer or service provider attesting that the equipment has been properly
installed, set up, and verified for the intended use will satisfy needed component documentation
requirements.
CONTRACTOR must be required to plan and coordinate work to ensure there will be no
unanticipated disruption in process operations and no hindrance of the District Representative’s
opportunity to witness calibration and loop checkout.
CONTRACTOR shall provide all test equipment necessary to perform the testing during system
checkout and startup.
CONTRACTOR shall be responsible for initial operation of the instrumentation and control
system and shall make any required changes, adjustments or replacements for operation,
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monitoring, and control of the various processes and equipment necessary to perform the
functions intended. Use Rockwell Software FactoryTalk AssetCentre application or other
application acceptable to the District to track and manage changes.
CONTRACTOR shall verify, set, and record all ranges, spans, parameters, setpoints, engineering
units, and other data required for the complete checkout and operation of the instrumentation and
control system.
CONTRACTOR shall furnish to the ENGINEER certified calibration reports for field and panel
instruments and devices specified in the Contract Documents as soon as calibration is completed.
Receipt of any calibration certificate by the District shall in no way imply acceptance of any
portion of the work or any products furnished by the CONTRACTOR.
The calibration certificates shall be prepared and furnished by the CONTRACTOR. All
calibration data pertinent to each individual instrument shall be provided on the calibration
certificates.
Each calibration certificate shall be signed and dated by the person performing the calibration
and by an authorized representative of the CONTRACTOR. Three copies of each completed
certificate shall be submitted to the ENGINEER.
CONTRACTOR shall furnish to the ENGINEER two copies of an installation inspection report
certifying that all equipment has been installed correctly and is operating properly. The report
shall be signed by an authorized representative of the CONTRACTOR and the CONTRACTOR..
9.2.J - Commissioning
Following the instrumentation and control system checkout and initial operation, the System
Integrator, under the supervision of the CONTRACTOR, shall perform a complete system test in
the presence of the ENGINEER to verify that all equipment is operating properly as a fully
integrated system and that the intended monitoring and control functions are fully implemented
and operational. CONTRACTOR shall provide assistance to the System Integrator.
Commissioning can only begin when all instruments are installed, wired and field calibrated, the
FAT successfully completed, and instrumentation and control documentation updated. All spare
parts must be on site and accepted prior to Commissioning.
CONTRACTOR shall submit to the Engineer a schedule for Commissioning, including a
proposed start date, at least three weeks in advance.
Commissioning shall include, as a minimum, the following checks:
All wiring shall be checked at each termination point for correct type, size, color, insulation,
termination, and wire number.
9.2.K - Loop Verification
The proper wiring of each control loop shall be physically verified by the Contractor from the
field device terminals to the control processor including every intervening panel, terminal, or
device. Instruments and devices shall have been field-calibrated prior to conducting loop
verifications. Cable, conductor, terminal board, and terminal designations shall be verified and
documented as such on a copy of the loop diagram or equivalent schematic or wiring diagram.
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Verification shall be by signal tracing, continuity verification, or “ringing out”. Tags and labels
placed during construction shall not be considered adequate verification.
Each control loop shall be verified by injection of an appropriate pressure, resistance, voltage
signal, or current signal. Use actual signals where available.
•
Closely observe controllers, recorders, alarm and trip units, remote setpoints, ratio
systems, and all other control and monitoring components. Observe HMI and OIT
graphical screens to verify appropriate linking of I/O and the response of the graphical
objects/symbols as well as associated alarm and event triggers displayed on graphical
screens. Observe that logging of alarm and events associated with I/O are correct.
Observe proper recording/archiving of I/O in the Historian. Make corrections as required
where invalid readings or responses are observed. Following any corrections, retest the
loop to verify proper operation.
•
Stroke all control valves, cylinders, drives, actuators, dampers, and connecting linkages
from each local and remote operator interface, including the control system operator
interface.
•
Check all hardwired interlocks to the maximum extent possible. In addition to any other
as-recorded documents, record all setpoint and calibration changes on the appropriate
system documentation.
•
All analog PID control loops shall be tuned for optimum response using an appropriate
loop tuning method and the resulting proportional, integral, and derivative values
recorded on the loop checkout sheet.
•
A Control Loop Checkout sheet shall be completed for each loop. A detailed description
is given in Paragraph 9.2.Q.
9.2.L - Functional Performance Testing (FPT)
Performance testing of all systems should be performed to verify compliance with the specified
sequences of operations, control descriptions, and control diagrams. Functional performance
testing consists of executing written step-by-step procedures in which a condition is initiated or
simulated and the response of the system is noted and compared to the specified or desired
response. Functional performance tests must verify the following:
•
Manual and automatic control modes.
•
Normal system conditions and modes of operation.
•
Contingency conditions and modes of operation.
•
Effect of all operator controls.
•
Operation of all interlocks and permissives.
•
Confirmation of failure state of all outputs.
•
Physical and information security measures.
If the configuration and programming of the PLC (programmable logic controller) or other
controller, local HMI and/or remote HMI is in the System Integrator’s scope of work then
corrections to the software, components, or systems are the responsibility of the System
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Integrator. Corrections to these systems shall be done using Rockwell Software FactoryTalk
AssetCentre or other District approved change management tools and procedures. It must be
kept in mind that changes made to correct misoperation at one point in the PLC control sequence
may inadvertently affect the performance of other control sequences that have already been
tested and accepted. (See Re-Commissioning, Paragraph 9.2.M).
9.2.M - Re-commissioning
Whenever all or part of a SCADA system is modified, repaired, or replaced (by any party), recommissioning is required to verify that the portions of the system affected function correctly
and that the work has not affected other portions of the system. The extent of re-commissioning
required shall be determined from the extent of the modifications.
For work that affects only devices and wiring external to the controller, the affected loops shall
be verified and functionally tested.
For changes to controller program logic or settings, the entire process or subsystem supported by
that controller shall be functionally tested, and the interface to the local and remote HMI
verified. Control software changes shall be managed using Rockwell Software FactoryTalk
AssetCentre application.
More extensive modifications may require re-commissioning of the complete SCADA system.
Functional performance testing for system certification must take place without operator
intervention in the processor from beginning to end of the test. For this reason, a complete pretest shall be conducted, using the full functional performance test procedure, prior to undertaking
the certification test.
9.2.N - Availability testing
Before final turnover of the system to the NEORSD, the System Integrator shall be responsible
for performing availability testing. The test shall determine system availability over a period of
time to be determined by the NEORSD. Availability is defined as the ratio of uptime to uptime
plus downtime. The passing availability ratio shall be determined by the NEORSD. For most
tests downtime shall be equal to zero units of time.
If availability testing criteria are not met over the testing period, then the System Integrator shall
re-start the testing from the beginning of the defined period of time.
9.2.O - Instrument Certification Sheet
Prior to loop and functional performance testing, all sensors and instruments shall be calibrated
and documented using an Instrument Certification Sheet. Each Instrument Certification Sheet
should include four sections as follows:
1. The Project and Instrument Description section which shall include:
•
Project Name
•
Project Location
•
District Project Number
•
Control Loop Number
•
Drawing References (such as P&ID, wiring diagram, etc.)
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•
Instrument Tag Number
•
Asset Number (if assigned)
•
Instrument Description
•
Instrument location
•
Instrument manufacturer
•
Instrument model number
•
Instrument serial number, if applicable
•
Instrument range
•
Calibrated signal range
•
Instrument setpoint and deadband (for switches)
2. Calibration equipment section: The certification sheet shall include the following
information on the calibration equipment used:
•
Type of Device
•
Manufacturer and Model Number
•
Accuracy
•
NIST Traceability (Yes/No)
3. Calibration Results section: The calibration results shall be entered on a table that is
suitably sized and formatted for the type of instrument/device being calibrated. This
include:
•
A table to record the calibration of analog instrumentation and devices such as
transmitters, analyzers and indicators
•
A table to record the calibration of process switches and other fieldconfigurable/calibratable sensing devices
A record of the transmitter, analyzer and indicator calibrations shall contain the
following
data for both increasing and decreasing input signals at 0, 25, 50, 75, and 100 percent of span:
•
Input value
•
Output value
•
Integral display reading (for instruments having a factory installed display
•
Span: the difference between the Maximum (upper range value) and
Minimum (lower range value) calibrated values of the instrument
•
Error: ((Output – Input)/Span) x100 %
A record of the process switch calibrations shall contain the following data for both increasing
and decreasing inputs at all setpoints:
•
Setpoint value
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•
Operate value
•
Reset value
•
Error: (Setpoint value – Operate value) units
4. Attestation Section: The calibration sheet shall include the following information
identifying the persons responsible for performing the calibration and witnessing the
calibration:
•
Printed name and dated signature of the SI/I&C SubCONTRACTOR
Representative responsible for the calibration.
•
Printed name and dated signature of the District’s Representative responsible
for witnessing the calibration.
•
Printed name, dated signature, and company affiliation of the lead person that
actually performed the calibration.
9.2.P - Final Control Element Certification Sheet
Valve actuators and other final control elements shall be calibrated and documented. A final
control element certification sheet shall include four sections:
1. The Project and Final Control Element Description Section which shall include the
following information:
•
Project Name
•
Project Location
•
District Project Number
•
Control Loop Number
•
Drawing References (such as P&ID, wiring diagram, etc.)
•
Control Valve Tag Number
•
Asset Number (if assigned)
•
Control Valve Description
•
Control Valve Location
•
Control Valve Manufacturer
•
Control Valve Model Number
•
Control Valve Serial Number, if applicable
•
Control Valve Actuator (Pneumatic or Electric)
•
Control Valve Positioner (Direct or Reverse), if applicable
•
Control Valve Positioner Input and Output Signal, if applicable
•
Control Valve I/P Converter Input and Output Signal, if applicable
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•
Control Valve Failure Mode (open or close) on air failure, if applicable
•
Control Valve Failure Mode (open or close) on signal loss, if applicable
2. The Calibration Equipment Section: The certification sheet shall include the
following information on the calibration equipment used.
•
Type of Device
•
Manufacturer and Model Number
•
Accuracy
•
NIST Traceability (Yes/No)
3. Calibration Results section: The calibration results shall include a table that is
suitably sized and formatted for the type of final control element being calibrated and
the completeness of the specified calibration requirements.
•
A table to record the calibration of the I/P (current to pneumatic) converter, if
applicable
•
A table to record the calibration of the final control element
•
A record of the I/P (current to pneumatic) converter calibration shall contain
the following data for both increasing and decreasing inputs at 0, 25, 50, 75,
and 100 percent of span:
a) Input value
b) Output value
c) Error ((Output – Input)/Span)x100 %
•
A record of the final control element calibration shall contain the following
data for both increasing and decreasing inputs at 0, 25, 50, 75, and 100 percent
of span:
a) Input value
b) Output travel (position) Travel: the valve percent open (not all valves
are linear)
c) Error ((Output – Input)/Span)x100 %
4. Attestation Section: The calibration sheet shall include the following information
identifying the persons responsible for performing the calibration and witnessing the
calibration:
•
Printed name and dated signature of the SI/I&C Sub-CONTRACTOR
Representative responsible for the calibration.
•
Printed name and dated signature of the District’s Representative responsible
for witnessing the calibration.
•
Printed name and dated signature and company affiliation of the lead person
that actually performed the calibration.
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Analog Loop Signal Processing and Operator Interface Device Certification Sheet
Prior to loop and functional performance testing, all analog loop signal processing devices (e.g.,
hardwired signal converters and function relays), and operator interface devices (e.g., panelmounted process indicators, loading stations, controllers) shall be calibrated/configured and
documented using a Loop Signal Processing Device and Operator Interface Device Certification
Sheet. Each Loop Signal Processing Device and Operator Interface Device Certification Sheet
should include four sections as follows:
5. The Project and Device Description section which shall include:
•
Project Name
•
Project Location
•
District Project Number
•
Control Loop Number
•
Drawing References (such as P&ID, wiring diagram, etc.)
•
Instrument Tag Number
•
Instrument Description
•
Instrument location
•
Instrument manufacturer
•
Instrument model number
•
Instrument serial number, if applicable
•
Instrument range
•
Instrument setpoint and deadband (as applicable)
6. Calibration equipment section: The certification sheet shall include the following
information on the calibration equipment used:
•
Type of Device
•
Manufacturer and Model Number
•
Accuracy
•
NIST Traceability (Yes/No)
7. Calibration Results section: The calibration results shall be entered on a table that is
suitably sized and formatted for the type of instrument/device being calibrated. This
includes:
•
A table to record the calibration of analog loop devices
•
A table to record the calibration of process event trips
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•
A record of the analog device calibration shall contain the following data for
both increasing and decreasing input signals at 0, 25, 50, 75, and 100 percent
of span:
a) Input value
b) Output value
c) Display reading
d) Span: the difference between the Maximum (upper range value) and
Minimum (lower range value) calibrated values of the instrument
e) Error: (Output – Input) / Span x 100%
•
A record of the process event trip calibrations shall contain the following data
for both increasing and decreasing inputs at all setpoints:
a) Setpoint value
b) Operate value
c) [Reset value]
d) Error: (Setpoint value – Operate value) units
8. Attestation Section: The calibration sheet shall include the following information
identifying the persons responsible for performing the calibration and witnessing the
calibration:
•
Printed name and dated signature of the CONTRACTOR’s Representative
responsible for the calibration.
•
Printed name and dated signature of the District’s Representative responsible
for witnessing the calibration.
•
Printed name and dated signature and company affiliation of the lead person
that actually performed the calibration.
9.2.Q - Control Loop Checkout Sheet
The Contractor shall perform loop checkouts for each control loop in the system and provide
suitable documentation certifying that the loop is properly tuned and operating correctly. Record
keeping and generation of documentation shall be facilitated electronically with the use of MS
Excel spreadsheet or MS Access applications, at the preference of the District. The control loop
checkout sheet shall have a section verifying each of the six steps described below. When these
have been verified and signed off, the functional performance testing (FPT) can be started.
•
Verify mechanical field installation and that there are no leaks
a) Motors and Pumps
b) Valves and Dampers
•
Verify that all Instruments are calibrated correctly for the specified
ranges and setpoints
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a) Pressure Instruments
b) Flow Instruments
c) Level Instruments
d) Temperature Instruments
e) Analysis Instruments
•
Verify electrical power wiring
a) Incoming power sources for proper voltage
b) Field and panel cables properly installed and identified
c) Circuit breakers sized and operating correctly
d) Fuses sized correctly
•
Verify control system Input and Output wiring
a) Digital inputs (for example, switches)
b) Digital outputs (for example, on / off signals)
c) Analog inputs (transmitters)
d) Analog outputs (VFDs, valves, and meters)
•
Verify software logic is complete
a) Correct programs are loaded
b) Factory Acceptance Test (FAT) thoroughly completed
c) Software Management Practices in place
•
Verify HMI (or OIT) points and displays are complete
a) Graphic screens and screen navigation
b) Alarm screens and operator actions
c) Trend Displays and Data Archiving configured properly
The I/O checkout software logic and HMI / OIT should have been verified during the factory
acceptance test.
The Control Loop Checkout Sheet shall have a section verifying each of the steps described
above. When these have been verified and signed off, the Functional Performance Testing can
be started.
All instruments and devices shall be checked to verify compliance with the specifications and
approved shop drawings. The calibration of analog devices shall be verified including the zero
and span.
Analog wiring shall be checked for correct polarity and ground continuity
termination point in the loop.
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All analog loops shall be verified at each termination point at 0%,
100% signal levels.
25%, 50%, 75%, and
CONTRACTOR shall provide the following documentation for use during the Commissioning
effort. This documentation is in addition to any documentation required by the Contract.
Complete field wiring and loop diagrams
Completed Calibration Certificates for all field devices which require adjustment or calibration.
CONTRACTOR shall provide one set of Commissioning documentation for the OWNER’S
personnel, one set for the ENGINEER’S use, one set for field use, and the required number of
sets for the CONTRACTOR’S use.
The documents corrected and modified during commissioning shall form the basis for the “AsBuilt” set of drawings. Updates to documents and drawings shall be done electronically. Handmarked “As-Built” documents are not acceptable.
9.2.R - I/O Checkout Certification Sheet
The I/O Checkout sheet certifies correctness of assignments of I/O, configuration of I/O
modules, and associations between I/O and control system HMI, OIT, alarm log, event log, and
Historian applications. Checkout with regard to HMI and OIT shall include process and
maintenance/diagnostics screen verification. The I/O checkout certification sheet shall be
completed during the Factory Acceptance Test for each I/O to document verification and shall
consist of the following sections.
9. The Project and Instrument/Field Device Description section which shall include:
•
Project Name
•
Project Location
•
District Project Number
•
I/O Point Tag Number (see Part II, 1.9 for Wonderware HMI)
•
I/O Point
Connection
Address
(physical/wired
PLC/Rack/Position/Channel and networked address
network/node (see Part V Section 5.3.B)
•
Drawing References (such as P&ID, loop drawing, wiring diagram, etc.)
•
Instrument/Field Device Tag Number
•
[Instrument Asset Number (if assigned by District)]
•
Instrument/Field Device Description
•
Instrument/Field Device location
•
Instrument/Field Device range
•
Instrument/Field Device setpoint and deadband (as applicable)
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10. I/O generation section: The certification sheet shall include the following information
describing the generation method (physical or simulated) used for each I/O tested:
•
I/O generation method (physical or simulated)
•
Test signal engineering units and span
•
Test Equipment Manufacturer/Model No./NIST calibration date (physical I/O
generation)
A record of the analog I/O checkout shall contain the following data for both increasing and
decreasing input signals at 0, 25, 50, 75, and 100 percent of normal operating span. In addition,
analog I/O shall be verified for out of range (bad quality).
•
Input value and corresponding engineering units
•
Output value and corresponding engineering units
•
Low bad signal quality limit value
•
High bad signal quality limit value
11. HMI, OIT Graphical Interface verification section: The certification sheet shall
include the following information about each graphical window of each system
graphical interface that utilizes the I/O:
1. Type of graphical interface (HMI (Wonderware), OIT (PanelView))
2. OIT Application Name
3. Graphical interface graphic window name (see Part V, Section 2.10F for HMI
window names and Part V, Section 4.4B for OIT display names)
4. Graphical object tag number
5. Graphical symbol
12. Attestation section: The I/O Checkout certification sheet shall include the following
information identifying the persons responsible for performing and witnessing the I/O
checkout:
6. Printed name and dated signature of the SI/I&C Subcontractor Representative
responsible for the I/O checkout.
7. Printed name and dated signature of the District’s Representative responsible
for witnessing the I/O checkout.
8. Printed name and dated signature and company affiliation of the lead person
that actually performed the I/O checkout.
9.2.S - Component Settings Record
The Contractor shall document all programming configuration settings associated with I/O points
created, added, or modified under the project in the Component Settings Record. The
Component Settings Record shall be a spreadsheet that documents each signal type and range,
high and low signal range limits, alarm and operating limits, trip settings, discrete point
open/closed signal state descriptors, filters, and deadbands associated with each I/O point. It
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shall identify the Project Name, Project Location, District Project Number and shall include the
following information fields:
9. I/O, instrument/field device identification fields:
•
I/O Point Tag Number (see Part II, 1.9 for Wonderware HMI)
•
I/O point description
•
I/O point type (distinguish networked I/O by suffix designating network type
(e.g., “–DN” (DeviceNet), “-MB” (Modbus))
•
I/O Point
Connection
Address
(physical/wired
PLC/Rack/Position/Channel and networked address
network/node (see Part V Section 5.3.B)
•
Drawing References (such as P&ID, panel drawing, loop drawing, wiring
diagram, etc.)
•
Instrument/Field Device Tag Number and Asset Number
•
Analog I/O point signal and process parameter definition fields
•
I/O raw signal engineering units (e.g., millivolts, volts, milliamps, psig, etc.)
•
Analog I/O raw signal span minimum value and maximum value (e.g., 4-20,
1-5, 24vDC, etc.)
•
I/O signal process parameter engineering units
•
I/O signal process parameter span minimum value and maximum value
•
Low bad signal quality limits lower value, upper value
address;
e.g.,
PLC/DeviceNet
10. Discrete I/O point signal and process parameter definition fields
•
Set state function description
•
Reset state function description
11. I/O point user interface association fields
•
HMI (none, AOI, UDT)
•
HMI Node and User Control Prohibit (identify nodes and user group types
that are not permitted to affect output state or value)
•
OIT (none, AOI, UDT)
•
OIT User Control Prohibit (identify user group types that are not permitted to
affect output state or value)
12. I/O point signal and process parameter alarm, trend and historian definition fields
•
I/O raw signal engineering units
•
I/O raw signal Low-Low Alarm value, Low Alarm value, High Alarm value,
High-High Alarm value
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•
I/O signal process parameter engineering units
•
I/O signal process parameter Low-Low Alarm value, Low Alarm value, High
Alarm value, High-High Alarm value
•
Alarm deadband
•
Alarm initiation delay time
•
Alarm cut-out delay time
•
Alarm priority rating
•
HMI Trended point
•
OIT Trended point
•
Historical data capture criteria and conditions (none, sampling period,
exception deadband, max time between archived samples, rate-of-change
limit, other criteria as applicable)]
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Part III CONTROL NETWORK
SECTION 1 - EASTERLY WWTP NETWORK BLOCK DIAGRAM
Part III - Control Network
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SECTION 2 - SOUTHERLY WWTC NETWORK BLOCK DIAGRAM
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SECTION 3 - WESTERLY WWTC NETWORK BLOCK DIAGRAM
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Part IV APPENDICES
SECTION 1 - WIRE TAGGING AND NUMBERING CONVENTION
Section 1.0 - PLC-5 Wire Tagging and Numbering Convention
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Section 1.1 - ControlLogix Wire Tagging Convention
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SECTION 2 - SAMPLE CONTROL SCHEMATIC WITH PLC-5 WIRE
TAGGING
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SECTION 3 - PLC-5 PANEL SAMPLE INTERPOSING TERMINAL WIRE
TAGGING
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SECTION 4 - SAMPLE PLC-5 ENCLOSURE LAYOUT DRAWINGS
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SECTION 5 - SAMPLE PLC-5 DIGITAL I/O WIRING DRAWING
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SECTION 6 - SAMPLE PLC-5 ANALOG I/O WIRING DRAWING
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SECTION 7 - PROCESS, EQUIPMENT, AND PARAMETER
ABBREVIATIONS
Section 7.0 - Process Abbreviations
PROCESS ABBREVIATIONS
AA
AMBIENT AIR
AMN
AMMONIA
AS
ASH SLURRY
ASW
ATTEMPERATOR SPRAY WATER
BLDN
BLOWDOWN
BMS
BURNER MANAGEMENT SYSTEM
BFW
BOILER FEED WATER
BUS
ELECTRICAL BUS
CA
COMPRESSED AIR
CCW
CONDENSATE COOLING WATER
CEN
CENTRATE
CF
CENTRIFUGE FEED
CG
CH
CMBA
CN
CR
CW
DA
DAF
DI
DO
DB
DES
DISCHG
DR
DSS
DW
DMW
EAS
EG
EF_#
ES
CALIBRATION GAS
COOLING WATER
COMBUSTION AIR
CONDENSATE (STEAM)
CONDENSATE RETURN
COLD WATER
DRY ASH
DISSOLVED AIR FLOTATION
DISINFECION
DISSOLVED OXYGEN
DEWATERED BIOSOLIDS
DEGRITTED EASTERLY SLUDGE
DISCHARGE (GENERAL)
DRAIN
DEGRITTED SCREENINGS AND STRAININGS (OR SLUDGE)
DILUTION WATER
DE-MINERAILIZED WATER
EXCESS ACTIVATED SLUDGE
EXHAUST GAS
EFFLUENT (#= PLC ID)
EASTERLY SLUDGE
Part IV - Appendices
IV-16
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ESK
ER
FA
FOA
GBT
GT
GRS
GTO
HFA
HG
HW
HWR
HWS
IA
IM
IN
INC
ING
LS
MU
NG
NPW
OF
OS
OT
OUT
PA
PHOS
PNG
POL
PHFA
PRW
PSH
PW
RW
Part IV - Appendices
PROCESS ABBREVIATIONS
EASTERLY SKIMMINGS
ENERGY RECOVERY
FLUIDIZING AIR
FOUL AIR
GRAVITY BELT THICKENER
GRAVITY THICKENER
GREASE
GRAVITY THICKENER OVERFLOW
HEATED FLUIDIZING AIR
HOT GAS
HOT WATER
HOT WATER RETURN
HOT WATER SUPPLY
INSTRUMENT AIR
IMPULSE LINE
INLET or INTAKE (GENERAL)
INCINERATION
INJECTED NATURAL GAS
LIFT STATION
MAKEUP WATER
NATURAL GAS
NON-POTABLE WATER
OVERFLOW
OXYGEN SCAVENGER
OBJECT TRAP
OUTLET (GENERAL)
PURGE AIR
PHOSPHATE
PILOT NATURAL GAS
POLYMER
PREHEATED FLUIDIZED AIR
PROCESS WATER
PRIMARY SUPERHEATER
POTABLE WATER (CITY WATER)
RECIRCULATION WATER
IV-17
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SA
SAN
SBS
SFH
SG
SHST
SK
SND
SPH
SR
SS
SSH
SSW
ST
STM
SUC
SVT
SW
SWH
TCSTO
TEAS
TPS
TICS
TU
VFWL
VT
WD
WHR
WHS
WL
WTS
Part IV - Appendices
PROCESS ABBREVIATIONS
SECOND STAGE AERATION
SANITARY
STORED BIOSOLIDS
SLUDGE FEED HEADER
SCRUBBED GAS
SUPERHEATED STEAM
SKIMMINGS
SAND
SODIUM PHOSPHATE
SLUDGE RECYCLE
SLUDGE STORAGE
SLUDGE SUCTION HEADER
SCRUBBER SOLUTION WATER
STEAM
STORM WATER
SUCTION (GENERAL)
SAND VENT
SEAL WATER
SLUDGE WITHDRAWAL HEADER
THERMALLY CONDITIONED SLUDGE THICKENER OVERFLOW
THICKENED EXCESS ACTIVATED SLUDGE
THICKENED PRIMARY SLUDGE
THICKENED THERMALLY CONDITIONED SLUDGE
TRUCK UNLOADING
VACUUM FILTER WASTE LIQUOR (CENTRATE)
VENT
WITHDRAWAL
WASTE HEAT RETURN
WASTE HEAT SUPPLY
WASTE LIQUOR
WATER TREATMENT SYSTEM
IV-18
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Section 7.1 - Equipment Abbreviations
EQUIPMENT ABBREVIATIONS
Part IV - Appendices
ABS
AUTOMATIC BACKWASH STRAINER
AD
AIR DRYER
AS
AIR SEPARATOR
ASF
(TWIN) AUGER SCREW FEEDER
B
BOILER
BFC
BIOFILTER CELL
BFP
BACKFLOW PREVENTER
BHU
BIN HYDRAULIC UNIT
BIN
STORAGE BIN
BKR
BREAKER
BLW
BLOWER (was BL)
BP
BU
BYP
CCT
CEMS
CHHX
CHP
CNT
CND
CNP
CP
CTP
DAD
DAR
DS
DSP
DMP
DTNK
DWO
EC
EJ
ET
F
FB
FBKR
FIB
FIL
FLP
FOB
BOOSTER PUMP
BLENDING UNIT
BYPASS (GENERAL)
CHLORINE CONTACT TANK
CONTINUOUS EMISSIONS MONITORING SYSTEM
COOLING WATER HEAT EXCHANGER
COOLING WATER PUMP
CENTRIFUGE (was CN)
CONDENSATE DEAERATOR
CONDENSATE PUMP
COMPRESSOR
CONDENSATE TRANSFER PUMP
DESICCANT AIR DRYER
DRY AIR RECEIVER
DUPLEX STRAINER
DOME SPRAY PUMP
DAMPER
DAY TANK
DRY WEATHER OVERFLOW
ECONIMIZER
EXPANSION JOINTS
EXPANSION TANK
FAN
FREE BOARD
FEEDER BREAKER
FAN INBOARD BEARING
FILTER
FLUSHING PUMP
FAN OUTBOARD BEARING
IV-19
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FOA
FP
FPRT
FS
FST
FWP
G
GHU
HG
HOP
HPT
HUM
HX
IDF
IFP
IRR
INC
INS
LL
MBKR
MIB
MIST
MOB
MON
MP
MX
NGLS
NGS
P
PAC
PAT
PBU
PCS
PHB
PHBS
PHU
PHX
PLP
PWRM
PST
PRTR
RAD
RP
RST
Part IV - Appendices
Equipment Abbreviations
FOUL AIR
FEED PUMP
FEEDER PROTECTION
FILTER/SILENCER
FIRST STAGE SETTLING TANK
FEED WATER PUMP
GRINDER
GATE HYDRAULIC UNIT
HORIZONTAL GATE
HOPPER
HYDROPNEUMATIC TANK
HUMIDIFIER
HEAT EXCHANGER
INDUCED DRAFT FAN
INCINERATOR FEED PUMP
IRRIGATE OR IRRIGATOR
INCINERATOR, FLUIDIZED BED (was FBI)
INLET SILENCER
LEAD-LAG
MAIN BREAKER
MOTOR INBOARD BEARING
MIST ELIMINATOR
MOTOR OUTBOARD BEARING
MONORAIL
MIXING PUMP
MIXER
NATURAL GAS LANCE SYSTEM
NATURAL GAS SYSTEM
PUMP
PROCESS AIR COMPRESSOR
POLYMER AGING TANK
POLYMER BLENDING UNIT
PRE-COOLER SECTION
PRE-HEAT BURNER
PRE-HEAT BURNER FUEL SUPPLY
PUMP HYDRAULIC UNIT
PRIMARY HEAT EXCHANGER
PIPE LUBRICATION PUMP
POWER MONITOR
PRIMARY SKIMMING (OR SETTLING) TANKS
PROTECTION RELAY
REFRIGERATED AIR DRYER
RECIRCULATION PUMP
RECTANGULAR STORAGE TANK
IV-20
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Part IV - Appendices
SB
SBCS
SC
SD
SG
SGU
SHX
SIL
SP
SPF
SPS
SSB
SST
STC
STK
STL
STNK
STR
STU
SV
SWO
TDP
TMS
TNK
TP
TPR
TRAY
TVS
UP
UPS
V
VFD
VNTI
WAR
WB
Equipment Abbreviations
SOOT BLOWER
SOOT BLOWER CONTROL STATION
SCREW CONVEYOR
STEAM DRUM
SLIDE GATE
STEAM GENERATOR UNIT
SECONDARY HEAT EXCHANGER
SILO
SUMP PUMP
SLIDING PLATE FRAME
STANDBY POWER SUPPLY
SECOND STAGE BLOWER
SECOND STAGE SETTLING TANK
STEAM CONDENSER
STACK
STEAM TURBINE LUBE SYSTEM
STORAGE TANK
STRAINER
STEAM TURBINE UNIT
SOLENOID VALVE
STORM WATER OVERFLOW
TANK DRAIN PUMP
TANK MIXING SYSTEM
TANK
TRANSFER PUMP
TRANSPORTER
IMPINGEMENT TRAY
TRANSIENT VOLTAGE SUPPRESSOR
UNLOADING PUMP
UNITERRUPTABLE POWER SUPPLY
VALVE
VARIABLE FREQUENCY DRIVE
VENTURI
WET AIR RECEIVER
WINDBOX
WG
WEIR GATE
WHB
WNDG
WSC
WASTE HEAT BOILER
WINDINGS
WET SCRUBBER
IV-21
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Section 7.2 - Parameter Abbreviations
Parameter Abbreviation
Conductivity
Concentration
Current
Flow Rate
Kilovolts
Kilowatts
Level
Megawatts
pH
Pressure
Differential Pressure
Temperature
Differential Temperature
Position
Speed
Torque
Turbidity
Vibration
MHO
CONC
AMP
FLW
KV
KW
LVL
MW
pH
PSI
PSID
TMP
TMPD
POS
SPD
TRQ
TRB
VIB
Others
Alarm
Average
Bypass
Backwash
Building
Command
Compute/Compensate
Interlock
Local
Lower
Fault, Failure
Feedback
Forward
ALM
AVG
BYP
BKW
BLDG
CMD
COMP
ILK
LOC
LWR
FLT
FDBK
FWD
Part IV - Appendices
High
and
Low HH, H, L, LL
(applied to alarms or
interlocks)
Maintenance
Modbus, ModbusPlus
Pushbutton
Remote
Residual
Reverse
Runtime
Setpoint
Upper
IV-22
MAINT
MB, MBP
PB
REM
RSDL
REV
RT
STPT
UPR
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Part V ControlLogix/Wonderware/PanelView Plus 6
SECTION 1 - INTRODUCTION
The following sections include standards for developing process control logic and graphics using
Rockwell Software RSLogix5000, Wonderware Archestra IDE, and Rockwell Software
FactoryTalk View.
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SECTION 2 - WONDERWARE STANDARDS AND CONVENTIONS
Section 2.0 - Introduction
The following sections detail the required standards and provide development guidance for
process screens and related components that collectively are the NEORSD Wonderware HMI
Monitor and Control System (MCS). These screens allow plant operators to perform the
required process control and monitoring functions from Area Control Stations (ACSs) located
throughout the plant.
Section 2.1 - Wonderware ArchestrA Key Concepts
The ArchestrA product contains key concepts that need to be understood in order to plan, design,
and implement an application. Some key concepts include DA Servers (supply data to client
nodes), Alarm DB Logger Manager, Application Servers, Galaxy Repository, Historian,
Information Server, and HMI clients.
At NEORSD there will be a SuiteLink Client instance for each PLC in the system (ControlLogix
or PLC5/SLC500).
• For PLC5 or SLC500, the specific SuiteLink Client instances will contain a mapping
conversion table that provides the link between standard object attributes and the PLC
data registers. The DASABTCP IO Server is used.
• For ControlLogix, the SuiteLink will communicate via DASABCIP I/O server directly
to the tag names in the processor without the need for the mapping conversion table or
PLC5 SuiteLink Client instances. The DASABCIP IO Server is used.
In order to successfully connect a PLC to Wonderware, the DAServers must be set up to poll the
PLC using the appropriate protocol (DASABTCP or DASABCIP), and the PLC must have a
properly configured Suitelink instance within the NEORSD Galaxy.
ArchestrA objects run within engines that are hosted on Application Servers. The Application
Servers are load sharing redundant servers (no less than two per site hosted in different physical
locations for “fox-hole” redundancy) and are capable of completely running the system in the
event of a server failure. InTouch Applications providing the runtime process screens are
deployed to individual clients within the galaxy. The system runs in a Server-Client
configuration where the Application Servers host the galaxy (ArchestrA database) and the clients
display the information. At NEORSD most of the clients will be deployed as thin-client
machines hosted on redundant servers.
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Section 2.2 - Simplified Network Architecture
*network representation below is currently in development
AOS #1
(Redundant)
AOS #2
(Redundant)
DA Server
(Pri)
Historian
Historian
GR Node
SQL Server
SQL Server
Thin Client
Farm
DA Server
(Bck)
Thin Client
Server 1
ArchestrA
Eng1
(Pri)
Eng2
Bck
Crossover
For
Redundancy
Crossover
For
Redundancy
Eng2 Eng1
(Pri) Bck
Thin Client
Server 2
DASABTCP
AB PLC5
(Ethernet)
AB PLC5
(Ethernet)
DASABCIP
AB ControlLogix
(Ethernet)
AB ControlLogix
(Ethernet)
AB ControlLogix
(Ethernet)
AB PLC5
(Ethernet)
System Features
Single Galaxy Repository Server
Redundant AOS Servers for each processing site
Redundant DA Servers for each processing site
Redundant Thin Client Servers for each processing site
Historian Store Forward (prevents data-loss by locally buffering data in the event the primary
historian connection is lost)
Section 2.3 - Software
2.3.A - New Applications
All new applications are required to be developed using the latest available NEORSD provided
galaxy CAB file (or equivalent). This export will contain all the currently available (released)
standard library objects and InTouch application to support development activities.
This export will be re-created periodically as functional elements are added and/or enhanced.
Additionally, other exports will be created “as required” in order to maintain an appropriate level
of application consistency between the NEORSD master galaxy and any standalone in
development copies.
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The NEORSD Wonderware HMI is a managed InTouch application which has been developed
using custom NEORSD developed library template objects. Refer to NEORSD Standard Object
Library User Manual for details on the currently available object template library.
Note: No InTouch tags (placeholders) are to be used without NEORSD pre-approvals. All
operator screens shall be constructed using NEORSD template objects and graphic symbols.
All new applications are required to be developed within software environments that use
matching application software revisions, applied hot fixes, patches etc to those at NEORSD.
Software developed using outdated revisions will not be accepted for import into the NEORSD
galaxy.
Section 2.4 - Security Design
2.4.A - Platform / Application Security
• Authentication Mode = OS Group Based (security model)
• Configurable Intervals
 Security Groups:
o 18_Opers
o 2798_Opers
o Admin
o Managers
o Default
 Users and Roles:
o Administrator
o Default
o HMI Programmer
o 18_Opers
o 2798_Opers
o Facility_Managers
o Domain Programmers
o REF_Programmers
o Administrators
• User ID and Password Authentication = OS Group Based
• By default, setpoint changes are allowed by normal operator access.
District operations/PC&A must determine and configure specific instances
where set point editing is NOT standard procedure for operators.
2.4.B - ArchestrA Role – Default
• View only, no ArchestrA or InTouch permissions.
• Print displays
• Access level = 0
• General permissions = None
• Operational permissions = None
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2.4.C - ArchestrA Role – 18_Opers
• No ArchestrA permissions.
• Able to perform basic controls within InTouch (turn pumps on/off,
open/close valves, change from auto/man, ect.) and specific setpoints
needed for operations.
• Only able to control equipment within specified areas (details to be
provided by district/Cimplicity).
• Access level = 500
• General permissions = None
• Operational permissions:
 18_Opers
o Can Acknowledge Alarms
o Can Modify “Configure” Attributes
o Can Modify “Operate” Attributes
o Can Modify “Tune” Attributes
2.4.D - ArchestrA Role – 2798_Opers
• No ArchestrA permissions.
• Able to perform basic controls within InTouch (turn pumps on/off,
open/close valves, change from auto/man, ect.) and specific setpoints
needed for operations.
• Only able to control equipment within specified areas (details to be
provided by district/Simplicity).
• Access level = 500
• General permissions = None
• Operational permissions:
 2798_Opers
o Can Acknowledge Alarms
o Can Modify “Configure” Attributes
o Can Modify “Operate” Attributes
o Can Modify “Tune” Attributes
2.4.E - ArchestrA Role – Facility_Managers
• No ArchestrA permissions.
• Able to perform basic controls within InTouch (turn pumps on/off,
open/close valves, change from auto/man, ect.) as well as setpoints
restricted to the operators.
• Access level = 1000
• General permissions = None
• Operational permissions:
 18_Opers
o Can Acknowledge Alarms
o Can Modify “Configure” Attributes
o Can Modify “Operate” Attributes
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o Can Modify “Tune” Attributes
 2798_Opers
o Can Acknowledge Alarms
o Can Modify “Configure” Attributes
o Can Modify “Operate” Attributes
o Can Modify “Tune” Attributes
2.4.F - ArchestrA Role – HMI Programmers/Domain Programmers/REF_Programmers
• All permissions of Facility_Manager plus restricted ArchestrA
permissions.
• Within ArchestrA will be able to derive new instances, create/edit
windows, ect.
• No permission to edit/create templates.
• Access level = 9000
• General permissions:
 IDE Permissions
o Can Start the IDE
o Importing and Exporting
 Can Utilize GalaxyLoad/GalaxyDump
o General Configuration
 Can Modify Deployed Instances
 Can Disable Change Comments
 Can Override Checkout
 Can Upload from Runtime
o System Configuration
 Can Create/Modify/Delete System Object Instances
(Platforms and Engines)
 Can Create/Modify/Delete Area Objects
o DeviceIntegration Objects
 Can
Create/Modify/Delete
DeviceIntegration
Object Instances
o Application Configuration
 Can Create/Modify/Delete Application Object
Instances
o Deployment Permissions
 Can Deploy/Undeploy System Objects
 Can Deploy/Undeploy Area Objects
 Can Deploy/Undeploy Application Objects
 Can Deploy/Undeploy DeviceIntegration Objects
 Can Mark an Object as Undeployed
o Graphic Management Permissions
 Can Create/Modify/Delete ViewApplications
 Can Deploy/Undeploy ViewApplications
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 SMC Permissions
o Can Start the SMC
o Can Start/Stop Engine/Platform
o Can Write to GObject Attributes using ObjectViewer
• Operational permissions = All
2.4.G - ArchestrA Role – Administrator/Administrators
• Default Wonderware user with full control of ArchestrA and InTouch.
• Access level = 9999 (*unchangeable)
• General permissions = All
• Operational permissions = All
2.4.H - Common Functions (InTouch)
• Inactivity Warning – If someone is logged into the system for more than
50 minutes without any activity on the HMI node the system will warn the
user of a pending Inactivity Automatic Logout.
• Inactivity Timeout – if someone is logged into the system for more than
60 minutes without any activity on the HMI node the system will
automatically log the user off the system.
• Disable ALT, ESC and Windows keys if the currently logged in user is
not an administrator
2.4.I - Electronic Records
• The InTouch wwalmdb database stores events and alarms with user
information within SQL on the historian.
• The analog values are stored in the runtime database within SQL on the
historian
• All InTouch event and alarm records are stamped with date and time
(UTC).
• In Wonderware electronic signatures are based on a combination of an
identification codes (User Name) and password.
• Preserving User Name uniqueness can be maintained assuming users are
disabled and never deleted. The NEORSD Automation group manages
this function with procedural controls.
SECTION 2.5 - COMMUNICATION DESIGN
2.5.A - ArchestrA IDE
The Integrated Development Environment (IDE) provides the interface to the configuration
aspects of the Application Server. From the IDE you manage templates, create object instances,
deploy, un-deploy, and perform functions associated with the development and maintenance of
the system.
The production Galaxy name is NEORSD_Production.
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2.5.B - Model View
The NEORSD model view is currently under development but will incorporate a site => process
location => equipment structure as indicated below:
NEORSD
Application
[S]Southerly
WWTP
[E]Easterly
WWTP
Collections and
Remote Monitoring
[W]Westerly
WWTP
Automated Regulator Sites
Flow Monitoring Sites
E[bld#]...
W[bld#]...
Level Monitor Sites
Rain Intensity Monitoring Sites
Remote Pump Stations
Odor Control Sites
Water Quality / Remote Monitoring and
Flow Management
S47
REF Building
S[bld#]...
S47
INC1
S47
INC2
Collections (EMSC Equipment)
S[bld#]...
S47
INC3
*Note: For the WWTPs the building number [bld#] closely follows the process areas.
2.5.C - Managed InTouch Application
The NEORSD Wonderware system has a Managed InTouch Application. In this model the
InTouch application is handled like an “object”. Derived “Instances” of this centralized InTouch
application are assigned to clients within the ArchestrA framework and deployed. Template
changes are automatically indicated within the “Instances” by a COTS supplied deployment
symbol. Until re-deployed the original configuration will continue to run. Deployed objects are
automatically loaded onto the clients, however, COTS software limitations may require manual
restarts of the thin client InTouch application which will be performed by the ACP Thin Client
Management Software.
2.5.D - Data Collection
The MCS system collects data directly from the PLCs in the field. The I/O Servers hosted on
each Application Server communicate with the PLCs on a facility wide Ethernet fiber network.
2.5.E - Tag Naming Standards
The tag naming standards and conventions are detailed in section 1.9 of this document.
SECTION 2.6 - BASE TEMPLATE LIBRARY (BTL)
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2.6.A - Introduction
The NEORSD Galaxy was created using the Wonderware provided quick-start library known as
the North American Base Template Library or BTL. The BTL represents a collection of
templates that enable three (3) common areas of functionality.
Linking an Application Object to a Device Integration Object
Configuring object lists about how the object is configured and where it exists in the Plant
Model.
Configurable ability to persist changes to user writeable attributes of the application objects
when undeploying and deploying the object. *Note: This feature uses XML stored locally on the
AOS server and by default is not redundant.
2.6.B - BTL Input Source Scripts
The BTL input source script operation
The BTL scripts auto populate the input sources of all instances when “---“ is found for the
default attribute value by making use of the following data format:
SuitelinkClientName.Topic.Instances.Attribute. For this scripting functionality to work the
object instance attribute name(s) found in the Wonderware tag database must have an identically
named PLC instance.attribute name(s).
Communication between the BTL input source script and non-object oriented PLCs
The Allen-Bradley PLC5s do not have an object oriented tagname.attribute database as they are
address mapped. Therefore, a conversion table is required and it exists within the Suitelink
object. This conversion table provides the linkage between the Wonderware tag database object
instance attribute(s) and the PLC5 mapping address (i.e. N80:20/1). In the future PLC5s will be
replaced by ControlLogix PLCs which have an object oriented tagname.attribute database
eliminating the need for this conversion table as they will talk directly to PLC AOIs or UDTs.
The BTL input source script and unused attributes on common object library templates
The BTL script that auto populates the attribute input sources is persistent and continues (every
30 sec) to try and locate a valid address posting a warning message into the logger for each
failure. Normally this is desired but what if you don’t care about a specific attribute because it is
not being used by the instance? For example an overload alarm is provided in the standard
library object template for a discrete motor but does not exist in a specific instance.
The solution involves the use of a Boolean Placeholder UDA which is inherited by all templates
and object instances in the Galaxy and “Me.Placeholder” entered for the attribute value. The
BTL input source script skips over “Me.Placeholder” when it is found and its internal source
mapping back to the UDA provides a valid connection target. This solution provides us with a
dummy placeholder for the unused attribute value that also removes the point from the I/O scan
count.
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*Note: It is required that all unused attributes within each object instance use “Me.Placeholder”
to remove these points from the I/O scan counts.
2.6.C - BTL Script Locations
The BTL scripts and UDAs are found on the “m” and “a” levels of the derived templates. These
are developed and maintained by Wonderware. After the BTL levels there is a separate template
created for development in which all other templates are derived. These templates will have the
prefix of NEORSD to clearly show they are created and maintained by the District. This creates
a centralized location for development that needs to be cascaded to all of the derived templates of
this type. See the example below for a visualization of the derivation of a template:
Note: Developers must avoid making any modifications to these vendor developed and
supported templates and/or scripts. ANY changes made to the application MUST be completely
documented and preserved such that they can be readily re-deployed should the next revision to
the BTLs be installed which likely would overwrite the modifications.
2.6.D - Data Logging Deadband
The templates are scripted to record or not record data with a deadband based upon the
Engineering or Operational Unit Range. The following lists the ranges and the deadband
required to record a change to the historian:
Range < 1
1 <= Range < 10
10 <= Range < 100
100 <= Range < 1000
Range >= 1000
Value Deadband = 0.0001
Value Deadband = 0.001
Value Deadband = 0.01
Value Deadband = 0.1
Value Deadband =1
The script writes the deadband to the attribute.ValueDeadband attribute under the history
settings. This attribute must remain unlocked on the template to allow the script to overwrite the
.ValueDeadband attribute.
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STANDARDS AND CONVENTIONS MANUAL
SECTION 2.7 - PLATFORM TEMPLATES
Each Platform Template is stored in the PlatformTemplates toolset. There are two toolsets that
will be used to derive all instances: NEORSD and PlatformTemplates.
2.7.A – AlarmSummary
Description
The Alarm Summary provides the AlarmSummary Query and Alarm Footer Query. The query
by default shows all of the alarms in the system but has custom filtering to allow the user to see a
number of different alarms and events.
Functional Details
• All alarming is handled by the ArchestrA System Platform Alarm Engine.
• Hosts the alarm summary page and footer
• Functionality redundantly hosted between AOS node pairs.
• Drop down box used to select between current alarms, historical alarms, events,
alarm state, and priority.
• String input box used to select the group main area.
• A separate alarm query for all system alarms.
Alarm Priorities
• Priority 1: Critical / High Importance
o Health and Human Safety Alarms (Chlorine High Level, Explosive Gas High
Level, etc.)
• Priority 2 - 500: Major / Medium Importance
o Permit violations ("High-High" and "Low-Low" levels) and catastrophic machine
failures.
• Priority 501 - 750: Minor / Low Importance
o Process variable excursions ("high" and "low" levels), non-catastrophic machine
failures and computer network failures.
• Priority 751 - 999
o Potential future alarm level
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Alarm Configuration
Alarms of different priorities are displayed on alarm summary pages using different colors to aid
in their identification. Color configuration for alarms is shown below.
Unacknowledged
Alarms
Acknowledged Alarms
Unack-Return Alarms
+ Flash Unack Alarms
Text/
Foreground
Alarm
Priority
Alarm
Level
Text/
Foreground
Background
Background
Text/
Foreground
1
High
White
Red
Red
White
White
2-500
Med
Black
Yellow
Yellow
Black
White
Gray
Gray
501-750
Low
White
Blue
Blue
White
White
Gray
751-999
*
White
Green
Green
White
White
Gray
Back-ground
*Note: 751 to 999 is being reserved for potential future development
Common Alarming Features
•
Alarm Indications
o Active alarms that are unacknowledged will blink with the alarm priority color
(Flash Unack Alarms)
o Active alarms that are acknowledged will stop blinking when acknowledged.
o Inactive alarms that are unacknowledged remain in the alarm summary queue
until cleared by acknowledgement.
Graphics
•
AlarmFooter
o Displays all the current alarms in the system. This graphic is also called:
a. AlarmFooter_Easterly
b. AlarmFooter_Southerly
c. AlarmFooter_Westerly
1
Graphic
Number
Design Element
Function
Description
1
FooterAlarmQuery
This graphic displays all of the alarms, sorted by the time of the alarms. The
column details of this section are State, TimeLCT, Name, Value,
AlarmComment, and Priority (thru alarm color).
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•
Alarm Summary
o Allows the user to see the Current Alarms/Events as well as Historical
Alarms/Events. The user may acknowledge a select or all alarms and add an
alarm comment. Filtering is also available to allow the user to sort by state,
priority, or area. Below is a screenshot of the AlarmSummary with a
description of each of the functions.
o This graphic is also called:
d. AlarmSummary_Easterly
e. AlarmSummary_Southerly
f. AlarmSummary_Westerly
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Graphic
Number
Design Element
Function
Description
1
DistrubutedAlarmQ
uery
This graphic displays all the current alarms.
2
Ack
Button
This graphic button
DistributedAlarmQuery.
acknowledge an alarm.
3
UnackAlarm
This graphic has a permanent query for only unacknowledged alarms and is
used to populate the System Unack Alarms output. This graphic is only
visible to users with administrative privileges.
4
CriticalAlarm
This graphic has a permanent query for only priority one alarms and is used to
populate the System Critical Alarms output. This graphic is only visible to
users with administrative privileges.
5
System
Unack
Alarms Number
This graphic displays the number of current System Unacknowledged Alarms
populated by the UnackAlarm query.
6
System
Critical
Alarms Number
This graphic displays the number of current System Critical Alarms populated
by the CriticalAlarm Query.
7
Dist Alarm Query
This string is populated with the server node that is providing the data for the
DistributedAlarmQuery.
This graphic is only visible to users with
administrative privileges.
8
Critical
Query
Alarm
This string is populated with the server node that is providing the data for the
CriticalAlarm. This graphic is only visible to users with administrative
privileges.
9
Unack
Query
Alarm
10
Start Time
This graphic displays a box in which the Start Time of a search can be
selected from the DistributedAlarmQuery. This option is only available for
historical alarms.
11
Type
This graphic displays
DistributedAlarmQuery.
12
ACK Button
This graphic button allows the user to acknowledge a select alarm. After this
button is pushed, but before the alarm is acknowledged, the user will be
prompted to enter an (optional) alarm comment.
13
State_Priority
This graphic displays the State or Priority of the selected alarm from the
DistributedAlarmQuery. This is only visible when Group Main Areas is equal
to ALL ALARMS.
14
ACK ALL Button
This graphic button allows the user to acknowledge all unacknowledged
alarms. After this button is pushed, but before the alarms are acknowledged,
the user will be prompted to enter an (optional) alarm comment.
15
End Time
This graphic displays a box in which the End Time of a search can be
selected from the DistributedAlarmQuery. This option is only available for
historical alarms.
16
Set Range
This graphic button allows the user to set the Range of Start and End Time
and when pressed, the DistributedAlarmQuery will display alarms from the
time range. This option is only available for historical alarms.
17
Group Main Area
This graphic alarm filter allows the user to input the name of an ArchestrA
area to see that area’s alarms. This is only visible when State/Priority is equal
to Default.
18
Reset Time Range
This graphic button resets the values in the Start Time and End Time boxes.
This option is only available for historical alarms.
Selected
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acknowledges the selected alarm from the
The user must be logged in to be able to
This string is populated with the server node that is providing the data for the
UnackAlarm. This graphic is only visible to users with administrative
privileges.
the
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Type
of
the
selected
alarm
from
the
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Graphic
Number
Design Element
Function
Description
19
Alarm Comment
This string input is where the user may enter an alarm comment. Click
area, enter the alarm comment, and hit enter. At this point you may OK
acknowledge alarm with comment or Cancel it. If the alarm comment is
blank, the current alarm comment in the alarm summary will remain and
alarm(s) will be acknowledged.
20
Alarm
Comment
Options
These graphic buttons allow the user to either OK or Cancel the Acknowledge
alarm operation.
21
Reset Filtering
This graphic button resets the area filtering back to the default. This is only
visible when filtering by area.
the
the
left
the
•
AlarmScreamer
o Popup that reopens/positions itself over every screen in the plant to notify
operators of the highest priority alarms that require immediate action.
o Naming Format: AlarmScreamer_plant, where plant is Easterly, Westerly,
Southerly, etc.
1
Graphic
Number
Design Element
Function
Description
1
ScreamerAlarmQuery
This graphic displays all of the screamer alarms, sorted by the time of
the alarms. The column details of this section are State, TimeLCT,
Name, Value, AlarmComment, and Priority (thru alarm color).
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•
Alarm Summary_System
o Displays all the current system alarms in the system. This graphic is also
called:
a. Alarm Summary_Easterly_System
b. Alarm Summary_Southerly_System
c. Alarm Summary_Westerly_System
1
3
4
2
Graphic
Number
Design Element
Function
Description
1
System Alarm Query
This graphic displays all of the system alarms, sorted by the time of the
alarms. The column details of this section are State, TimeLCT, Name,
Value, Alarm Comment, and Priority (thru alarm color).
2
Type
This graphic displays the Type of the selected alarm from the Distributed
Alarm Query.
3
ACK Button
This graphic button allows the user to acknowledge a select alarm..
4
ACK ALL Button
This graphic button allows the user to acknowledge all unacknowledged
alarms.
Instances
• Alarm Summary
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2.7.B – EngineForAlmLogService
Description
EngineForAlarmLogService activates and disables the Alarm Logging Service on each AOS
node and prevents both Alarm Loggers from running simultaneously. This is necessary to make
the alarm logging redundant and prevents historical alarms from being lost.
Functional Details
• Activates the redundant alarm logging engine on the backup AOS platform when a
failover event occurs. This script starts the alarm logging engine because there is not
any support in Server 2008 for this to run as a service.
• Based on location, the engine name in the Engine UDA must be updated.
General
Design Element
VALUE
Engine startup type
Auto
Engine Restart
Checked
Scan period
1000 ms
Enable storage to historian
Unchecked
Maximum
execute
time
for
scripts
Maximum
count
asynchronous
to
thread
1000 ms
5
Checkpoint period
0 ms
Checkpoint directory location
C:\Checkpoint
Alarm throttle limit
2000 alarms/s
Statistics average period
10000 ms
Maximum queue size
16 MB
Engine failure timeout
10000 ms
Maximum number of consecutive
data notification failures allowed
0
Redundancy
Design Element
VALUE
Enable redundancy
Unchecked
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R/W Interrupts
Design Element
VALUE
Number of read/write interrupts
5
Enable standard interrupts
Unchecked
Attributes
Attribute
DATA TYPE
Almdb_setservice
Boolean
AlmDBLogRunning
Boolean
Engine
String
DESCRIPTION
Turns the Alarm Logging Service on through the
setservice script
Checks to see on which node the Alarm Logger is
running
Provides engine name for setservice script, based
on location engine name must be changed
Scripts
Script
EXECUTION TYPE
DESCRIPTION
ALMDB
Execute
Restarts the engine when the platform changes
onscan
Execute
Setservice
Execute
Setservice
Shutdown
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Triggers the setservice script when the object is on
scan
Starts and Stops the Alarm DB Logger depending
on which platform the object is hosted
Kills the Logger Service when the object is
shutdown
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Graphics
• DBLoggerConnection
o The DBLoggerConnection graphic displays a constant string of ‘DB Logger
Status’ followed by a dynamic string value that says ‘Running’ in black when
the DBLogger is running and has a connection with the PLC and ‘Stopped’ in
black when it is not.
1
Graphic
Number
Design Element
Function
Description
1
DB Logger Status
This graphic string displays the status of the DB Logger. The string displays
Running and Stopped to show when the DB Logger is logging data.
Instances
•
•
•
•
•
•
EngineForAlmLogService_E_AOS1
EngineForAlmLogService_E_AOS2
EngineForAlmLogService_S_AOS1
EngineForAlmLogService_S_AOS2
EngineForAlmLogService_W_AOS1
EngineForAlmLogService_W_AOS2
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2.7.C - Historian
Description
The Historian object is used to trigger alarms based upon the historian’s condition.
Functional Details
• Creates alarms in the Galaxy if there are issues with the Historian that are not
generated by default within the Galaxy. Examples include Critical Alarms (if more
than x alarms generated), DataAcqRate, SysWarning, and SysFatalErrors.
Attributes
Attribute
Data Type
DESCRIPTION
ALARM PRIORITY
SysCritErrCnt
Integer
Total critical errors since startup. If above
the value of 3 an alarm will occur.
500
SysDataAcqOverallItems
PerSec
Integer
Items per second received from the historian.
If the value drops below 9 an alarm will
occur.
500
SysErrErrCnt
Integer
Total non fatal errors since startup. If the
value goes about 6 an alarm will occur.
500
SysFatalErrCnt
Integer
Total fatal errors since startup. If the value
goes about 1 an alarm will occur.
500
SysWarnErrCnt
Integer
Total warnings since startup. If the value
goes about 26 an alarm will occur.
750
Instances
• Southerly_Historian
• Westerly_Historian
• Easterly_Historian
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2.7.D - MenuBar
Description
The Menu Bar provides a drop down list of windows from tabs based upon the UDA values
entered on the instance.
Functional Details
• The tab name is configured via an ArchestrA UDA. A string may be entered in the
Tab##Caption UDA. This sting will display text on the ## tab. (## may be 1-12). The
Tab Caption controls the tab visibility.
• The tab navigation is also configured via a UDA. An array of strings of up to 15 may
be entered in the Tab##Menu UDA. For navigation to work each string must be an
InTouch window name.
• The home button will navigate to the respective Plant Overview screen depending on
Node.
• The Perm_Value display will be green if true, red if false.
• Tab 12 is used for links to diagnostic screens, and is only visible to administrators.
Attributes
Attribute
Data Type DESCRIPTION
Tab01Caption
String
String is caption on navigation tab 01.
Tab01Menu
String
String array are navigation links for tab 01.
Tab02Caption
String
String is caption on navigation tab 02.
Tab02Menu
String
String array are navigation links for tab 02.
Tab03Caption
String
String is caption on navigation tab 03.
Tab03Menu
String
String array are navigation links for tab 03.
Tab04Caption
String
String is caption on navigation tab 04.
Tab04Menu
String
String array are navigation links for tab 04.
Tab05Caption
String
String is caption on navigation tab 05.
Tab05Menu
String
String array are navigation links for tab 05.
Tab06Caption
String
String is caption on navigation tab 06.
Tab06Menu
String
String array are navigation links for tab 06.
Tab07Caption
String
String is caption on navigation tab 07.
Tab07Menu
String
String array are navigation links for tab 07.
Tab08Caption
String
String is caption on navigation tab 08.
Tab08Menu
String
String array are navigation links for tab 08.
Tab09Caption
String
String is caption on navigation tab 09.
Tab09Menu
String
String array are navigation links for tab 09.
Tab10Caption
String
String is caption on navigation tab 10.
Tab10Menu
String
String array are navigation links for tab 10.
Tab11Caption
String
String is caption on navigation tab 11.
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Attribute
Data Type DESCRIPTION
Tab11Menu
String
String array are navigation links for tab 11.
Tab12Caption
String
String is caption on navigation tab 12.
Tab12Menu
String
String array are navigation links for tab 12.
Graphics
• Menu_Bar: Allows the user to access custom navigation. When a tab is selected a
dropdown box allows access to the navigation. A home button and perm_value
display are included.
1
2 3
Graphic
Number
Design Element
Function
Description
1
Tab (1-12)
Theses tabs can be configured in ArchestrA via UDAs to provide custom
navigation.
2
Home Button
This graphical button will navigate the user to the Plant_Overview for each
NEORSD location.
3
Perm_Value Light
This graphical light will display green if the InTouch Perm_Value is true, red if
false.
Instances
• Southerly_Menu
• Westerly_Menu
• Easterly_Menu
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2.7.E - $NEORSDAOS
Description
The $NEORSDAOS represents a server in the automation application with redundancy and hosts
engines, areas, and instances.
Functional Details
• Additional layer from other platforms
• Provides a template for redundant AOS platforms
• The Alarm Provider which creates and manages alarms.
• History enabled to ensure all platform data is properly stored
• Store Forward enabled to locally store data to ensure data is never lost in the event of
a connection issue with the Historian
General
Design Element
VALUE
Network address
<blank>
Historian Store Forward Directory
C:\StoreForward
Minimum RAM
1024 MB
Statistics Average Period
10000 ms
Enable InTouch alarm provider
Checked
Redundancy
port:
30001
message
channel
Redundancy primary channel port:
30000
Register using “Galaxy…
Unchecked
Alarm Areas
<blank>
Message timeout
120000 ms
NMX heartbeat period
2000 ms
Cons number of missed NMX
3
Message exchange port
5026
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Engine
Design Element
VALUE
Engine startup type
Auto
Scan period
1000 ms
History –
historian
Enable
storage
to
Checked
History – Enable Tag Hierarchy
Checked
History – Historian
---
History –Store forward deletion
threshold
100 MB
History – Store forward minimum
duration
0s
History – Forwarding chunk size
1024 Byters
History – Forwarding delay
250 ms
History – Buffer count
128
Scripts – Maximum time for scripts
to execute
1000 ms
Scripts - Maximum asynchronous
thread count
5 threads
Checkpoint period
1000 ms
Checkpoint directory location
C:\Checkpoint
Alarm throttle limit
2000 alarms/s
Statistics average period
10000 ms
Maximum input queue size
16 MB
Engine failure timeout
10000 ms
Maximum number of consecutive
data notification failures allowed
0
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Graphics
• HistorianConnection
o The HistorianConnection graphic displays a constant string of ‘Historian
Connection Status’ followed by a dynamic string value that says ‘Connected’ in
black when the Historian has a connection with the PLC and ‘Disconnected’ in
red when the connection has been lost.
1
Graphic
Number
1
Instances
•
•
•
•
•
•
Design Element
Function
Description
Historian
Connection Status
This graphic display indicates the connectivity of the Historian showing either
Connected in black and Disconnected in red with the connection has been
lost.
ESDAP
ESDAR
SSDAP
SSDAR
WSDAP
WSDAR
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2.7.F - NEORSDAppEngine
Description
The NEORSDAppEngine hosts and schedules execution of Application Objects, Areas, and
Device Integration Objects.
Functional Details
• Provides redundancy between AOS platforms to ensure robust data acquisition
• Additional layer between the derived engines and $aAppEngine
• Supports flexibility of design if a common script/attribute/UDA needs created and is
common to all engines
• Addition of this layer supports manufacturer best practices and prevents need to alter
BTLs
• History enabled to ensure all data is properly stored
General
Design Element
VALUE
Engine startup type
Auto
Engine Restart
Unchecked
Scan period
1000 ms
History –
historian
Enable
storage
to
Checked
History – Enable Tag Hierarchy
Checked
History – Historian
---
History – Store forward deletion
threshold
100 MB
History – Store forward minimum
duration
0s
History – Forwarding chunk size
1024 Bytes
History – Forwarding delay
250 ms
History – Buffer count
128
History – Enable Late Data
Unchecked
Scripts – Maximum time for scripts
to execute
1000 ms
Scripts – Maximum asynchronous
thread count
5 threads
Checkpoint period
20000 ms
Checkpoint directory location
C:\Checkpoint
Alarm throttle limit
2000 alarms/s
Statistics average period
10000 ms
Maximum input queue size
16 MB
Engine failure timeout
10000 ms
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Design Element
VALUE
Maximum number of consecutive
data notification failures allowed
0
Redundancy
Design Element
VALUE
Enable redundancy
Checked
Forced failover timeout
90000 ms
Maximum
buffered
checkpoint
deltas
0
Maximum alarm state changes
buffered
0
Standby engine heartbeat period
1000 ms
Active engine heartbeat period
1000 ms
Maximum consecutive heartbeats
missed from Active engine
5
Maximum consecutive heartbeats
missed from Standby Engine
5
Maximum time to maintain good
quality after failure
120000
Maximum time to discover partner
15000
Restart engine process when
transitioning
from
Active
to
Standby
checked
R/W Interrupts
Design Element
VALUE
Number of read/write interrupts
5
Enable standard interrupts
Unchecked
Instances
•
•
•
•
•
•
ENG_ESDAP
ENG_ESDAR
ENG_SSDAP
ENG_SSDAR
ENG_WSDAP
ENG_WSDAR
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2.7.G - $NEORSDArea_Lower
Description
The Area represents a plant area and allows grouping of objects for modeling and alarm
reporting. The I/O BTL script by default searches the area for a Suitelink client for a connection
to the DAServer. This area looks at the containing area for the server name and topic for data
acquisition, which allows for areas within areas that do not require a separate
DDESuitelinkClient instance. In order for this to work, the top area must be derived from
NEORSDArea_Top and that area must contain a SuitelinkClient instance. Every area contained
within that Top Area will “look up” to the containing area for its I/O. The area derived from
NEORSDArea_Top is NEORSDArea_Lower.
Functional Details
• Additional layer between the derived engines and $aArea.
• Supports flexibility of design if a common script/attribute/UDA needs created and is
common to all areas
• Allows for entire area’s alarms to be disabled
Instances
• Instance name should match the PLC name, with a prefix that reflects the NEORSD
plant:
o Site designators are listed in Part II, Section 1.5.I of this document. A sample
listing is repeated below for convenience.
o Note: Southerly instances have no prefix as it plays host to the WW galaxy).
E
Control points within or from Easterly WWTC
W
Control points within or from Westerly WWTC
A
Automated Regulator sites
F
Flow Monitoring sites
L
Level Monitoring sites
R
Rain Intensity monitoring sites
P
Remote Pump Stations
O
Odor Control sites
Water Quality / Industrial Surveillance remote monitoring sites
and Flow Management
Collection system control facilities, however, its ongoing use
should be limited to points specifically associated with EMSC
building equipment.
U
C
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2.7.H - $NEORSDArea_Top
Description
The Area represents a plant area and allows grouping of objects for modeling and alarm
reporting. Through the BTL I/O Scripting, this area will look for a Suitelink Instance contained
within the area for its data. If other areas are contained within this area instance they should be
derived from $NEORSDArea_Lower and these areas will “look up” to the top area instance for
their data.
Functional Details
• Additional layer between the derived engines and $aArea.
• Supports flexibility of design if a common script/attribute/UDA needs to be created
and is common to all areas
• Allows for entire area’s alarms to be disabled
• Addition of this layer supports manufacturer best practices and prevents need to alter
BTLs
Instances
• Instance name should match the PLC name, with a prefix that reflects the NEORSD
plant:
o Site designators are listed in Part II, Section 1.5.I of this document. A sample
listing is repeated below for convenience.
o Note: Southerly instances have no prefix as it plays host to the WW galaxy).
E
Control points within or from Easterly WWTC
W
Control points within or from Westerly WWTC
A
Automated Regulator sites
F
Flow Monitoring sites
L
Level Monitoring sites
R
Rain Intensity monitoring sites
P
Remote Pump Stations
O
Odor Control sites
Water Quality / Industrial Surveillance remote monitoring sites
and Flow Management
Collection system control facilities, however, its ongoing use
should be limited to points specifically associated with EMSC
building equipment.
U
C
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2.7.I - $NEORSDClient
Description
The NEORSDWinPlatform_Client represents a client node in the application that is not a thin
client.
Functional Details
• Provides a template for each client node in the application that is not a thin client
• Removes the unnecessary functionally for a client included in the AOS and GR
Platforms
• Allows for data on a client.
General
Design Element
VALUE
Network address
<blank>
History store forward directory:
<blank>
Minimum RAM
1024 MB
Statistics Average Period
10000 ms
Enable storage to historian
unchecked
Redundancy
–
Redundancy
message channel IP address:
<blank>
Redundancy
–
Redundancy
message channel port
30001
Redundancy
–
Redundancy
primary channel port
30000
Message Exchange – Message
timeout
30000 ms
Message Exchange
heartbeat period
2000 ms
–
NMX
Message Exchange – Consecutive
number of missed NMX heartbeats
allowed
3
Message Exchange – Message
exchange port
5026
Design Element
VALUE
Engine startup type
Auto
Restart the engine when it fails
<blank>
Scan period
1000 ms
Enable storage to historian
unchecked
Engine
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Design Element
VALUE
Scripts – Maximum time for scripts
to execute
1000 ms
Scripts - Maximum asynchronous
thread count
5 threads
Checkpoint period
1000 ms
Checkpoint directory location
C:\Checkpoint
Alarm throttle limit
2000 alarms/s
Statistics average period
10000 ms
Maximum input queue size
16 MB
Engine failure timeout
10000 ms
Maximum number of consecutive
data notification failures allowed
0
Instances
•
•
•
•
•
•
ESTSP
ESTSR
WSTSP
WSTSR
SSTSP
SSTSR
2.7.J - $NEORSDDDESuiteLinkClient
Description
The $NEORSDDDESuiteLinkClient provides connectivity to DDE or SuiteLink I/O servers.
Functional Details
• Additional layer between the derived templates and $aDDESuiteLinkClient.
• Supports flexibility of design if a common script/attribute/UDA needs created and is
common to all areas
• Location of ServerFailOver script which is common to all areas and supports
redundant AOS platforms (switches active DA server to backup platform)
• Addition of this layer supports manufacturer best practices and prevents need to alter
BTLs
General
Design Element
VALUE
Detect connection alarm
Checked
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Design Element
VALUE
Priority
500
Communication protocol
SuiteLink
Attributes
Attribute
Data
Type
DESCRIPTION
BackupServer
String
Connection_Attempts
Integer
Connection_Retries
Integer
Name of Backup AOS node used by ServerFailOver script
Number of attempts made by the Suitelink Client before failing over
to the backup
Number of attempts to reconnect to the initial platform before
declaring a disconnect and failing over to the backup
PrimaryServer
String
Name of Primary AOS node used by ServerFailOver script
Scripts
Script
Execution
Type
DESCRIPTION
ReturnToPrimary
Execute
Attempts to reconnect to the primary node every 30 minutes
when gathering data through the backup node
ServerFailOver
Execute
Connects to the backup node when connection to the primary
DAServer is lost
Graphics
• Display
o This Display is directly taken from the default Wonderware graphic toolbox.
The object was created from DDESuiteLinkClientDisplay. One script and
custom property were added for the selection of the topic name through a drop
down list selection. This object describes the server hosting, the client, the
connection state, the scan state, and topic information.
•
Display – Alterations
o The following alterations were made to the display in order to custom design
the display to allow a drop down topic list, which is not in the default
configuration.
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1
Graphic
Number
Design Element
Function
Description
1
SuitelinkTopic
Drop down for the selection of topic name.
•
Node_Display
o This Node_Display Graphic shows the tagname of the object and the node that
it is connected to.
1
2
Graphic
Number
Design Element
Function
Description
1
Tagname
This displays the tagname of the object.
2
Node
This string displays the ServerNode that the object is hosted on.
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Instances
When naming the instances make the name match the name of the associated PLC followed by
“_SL”. For example if the PLC is named “SH” (solids handling) the contained SuiteLink
instance should be named “SH_SL”.
2.7.K - $NEORSDDDESuiteLinkClient_HIS
Description
The $NEORSDDDESuiteLinkClient_HIS provides connectivity to the SuiteLink I/O server on
the Historian. A separate Suitelink template is needed because the Historian does not have
redundancy.
Functional Details
• Provides connection to the historian to monitor the historian’s status and alarms
• Script included which reconnects to historian periodically if connection is lost
General
Design Element
VALUE
Server name
aahIOSvrSvc
Detect connection alarm
Checked
Priority
500
Communication protocol
SuiteLink
Topic
Topic
SCAN MODE
Tagname
ActiveAll
Scripts
Script
Execution
Type
DESCRIPTION
Reconnect
Execute
Reconnects to Historian after 5 minutes
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Graphics
• Display
o This Display is directly taken from the default Wonderware graphic toolbox.
The object was created from DDESuiteLinkClientDisplay. This object
describes the server hosting, the client, the connection state, the scan state, and
topic information.
Instances
•
•
•
NEORSDDDESuiteLinkClient_HIS_South
NEORSDDDESuiteLinkClient_HIS_West
NEORSDDDESuiteLinkClient_HIS_East
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2.7.L - $NEORSDGR
Description
The NEORSDGR represents a Galaxy Repository platform node in the application.
Functional Details
• Provides a template for each GR Platform in the system.
• Unneeded functionally such as enabling history and redundancy are not enabled
allowing for greater flexibility within the templates
• Designed so if connection to GRNode is lost the system will still properly operate
General
Design Element
VALUE
Minimum Ram
1024 MB
Statistics average period
10000 ms
Redundancy
–
Redundancy
message channel port
30001
Redundancy
–
Redundancy
primary channel port
30000
Message Exchange – Message
timeout
120000 ms
Message Exchange
heartbeat period
2000 ms
–
NMX
Message Exchange – Consecutive
number of missed NMX heartbeats
allowed
3
Message Exchange – Message
exchange port
5026
Design Element
VALUE
Engine startup type
Auto
Restart the engine when it fails
checked
Scan period
1000 ms
Scripts – Maximum time for scripts to
execute
1000 ms
Scripts - Maximum asynchronous thread
count
5 threads
Checkpoint period
0 ms
Alarm throttle limit
2000 alarms/s
Statistics average period
10000 ms
Engine
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Design Element
VALUE
Maximum input queue size
16 MB
Engine failure timeout
10000 ms
Maximum number of consecutive data
notification failures allowed
0
Instances
• Southerly_GR_Node
• Westerly_GR_Node
• Easterly_GR_Node
2.7.M - $NEORSDUserDefined
Description
The $NEORSDUserDefined represents the starting point for creating custom built objects that
include Discrete and Analog Attributes, UDAs, Scripts, Extensions, or Contained objects.
Functional Details
• Additional layer between the derived templates and $aUserDefined.
• Supports flexibility of design if a common script/attribute/UDA needs created and is
common to all areas
• Location of the Placeholder attribute which is distributed to all derived templates
• Addition of this layer supports manufacturer best practices and prevents need to alter
BTLs
Attributes
Attribute
Data Type
DESCRIPTION
Placeholder
Boolean
Used as an input source to disable the BTL input source auto
populate script
Instances
All derived object templates are derived from $NEORSDUserDefined, see derived object
documentation.
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2.7.N - $NEORSDViewEngine
Description
The $NEORSDViewEngines are placed on the thin client server or full client nodes and serve as
hosts of the managed InTouch application instances.
Functional Details
• Additional layer between the derived templates and $aViewEngine.
• Supports flexibility of design if a common script/attribute/UDA needs to be created
and is common to all View Engines.
• Addition of this layer supports manufacturer best practices and prevents need to alter
BTLs.
• Allows for data on a client.
General
Design Element
VALUE
Engine startup type
Auto
Scan period
1000 ms
Enable storage to historian
Unchecked
Scripts – Maximum time for scripts to
execute
1000 ms
Scripts - Maximum asynchronous thread
count
5 threads
Checkpoint period
0 ms
Checkpoint directory location
C:\Checkpoint
Alarm throttle limit
2000 alarms/s
Statistics average period
10000 ms
Maximum input queue size
16 MB
Engine failure timeout
10000 ms
Maximum number of consecutive data
notification failures allowed
0
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2.7.O - $NEORSDWinPlatform
Description
•
The NEORSDWinPlatform represents a server in the automation application and hosts
engines, areas, and instances. Platforms should not be derived directly from this template
but from the derived platform templates.
Functional Details
• Additional layer between the derived platforms and $aWinPlatform.
• Supports flexibility of design if a common script/attribute/UDA needs created and is
common to all engines
• Addition of this layer supports manufacturer best practices and prevents need to alter
BTLs
General
Design Element
VALUE
Minimum Ram
1024 MB
Statistics average period
10000 ms
Enable InTouch alarm provider
unchecked
Redundancy
–
Redundancy
message channel port
30001
Redundancy
–
Redundancy
primary channel port
30000
Message Exchange – Message
timeout
30000 ms
Message Exchange
heartbeat period
2000 ms
–
NMX
Message Exchange – Consecutive
number of missed NMX heartbeats
allowed
3
Message Exchange – Message
exchange port
5026
Design Element
VALUE
Engine startup type
Auto
Scan period
1000 ms
Enable storage to historian
unchecked
Scripts – Maximum time for scripts to
execute
1000 ms
Scripts - Maximum asynchronous thread
count
5 threads
Engine
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Design Element
VALUE
Checkpoint period
0 ms
Alarm throttle limit
2000 alarms/s
Statistics average period
10000 ms
Maximum input queue size
16 MB
Engine failure timeout
10000 ms
Maximum number of consecutive data
notification failures allowed
0
Instances
See derived instances from $NEORSDAOS, $NEORSDClient, and $NEORSDGR (above).
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2.7.P - $PrinterSelect
Description
The Printer Select Object is used to select a printer from the network and print.
Functional Details
• The PrintSelect printers are entered in the UDA PrinterList. Up to 5 printers may be
entered in the string array.
• The PrintSelect printer captions are entered in the UDA PrinterCaption.
Attributes
Attribute
Data Type DESCRIPTION
PrinterCaption
String
String array are for caption on Faceplate.
PrinterList
String
String array are for selecting printer on Faceplate.
Graphics
• PrinterSelectButton: Allows the user to open the PrinterSelect faceplate to select a
printer.
1
Graphic
Number
1
Design Element
Function
Select
Button
Description
Printer
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This graphical button allows the user to open the PrinterSelect faceplate to
select a printer.
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•
PrinterSelectFaceplate: Allows the user to select a printer
4
1
2
3
Graphic
Number
Design Element
Function
Description
1
Selected Printer
This string is populated with the selected printer after it is set.
2
Printer Options
The available printers configured in the ArchestrA object UDA array.
3
OK Button
The OK button will set the selected printer.
4
Close Faceplate
This will close the faceplate after a printer is selected.
Instances
• Easterly_PrintSelect
• Southerly_PrintSelect
• Westerly_PrintSelect
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2.7.Q - $Screen_Object
Description
The Screen Object contains a Node string array which restricts which InTouch windows can send
outputs based on which Node the view client is on.
Functional Details
• The screen object must be named same as the InTouch window.
• The Nodes where the window will be used are set in the UDA Node. The string array
can contain up to 32 node names.
Attributes
Attribute
Data Type DESCRIPTION
Node
String
String array are for setting nodes where window is
used.
Instances
The screen instances are to be hosted in the appropriate NEORSD plant area
(Easterly_Screen_Objects, Westerly_Screen_Objects, Southerly_Screen_Objects).
For example, screens developed for the Southerly plant would have the screen object instances
placed in the Southerly_Screen_Objects area.
The various plant areas already exist in the NEORSD galaxy, and should have been provided in
the base .cab file provided for Wonderware development.
SECTION 2.8 - DEVICE OBJECT TEMPLATE LIBRARY
All interfaces between PLC and Wonderware HMI applications will use a District approved
object. Refer to the NEORSD Standard Object User Manual for a list of the District approved
templates.
New ControlLogix applications should utilize the AOI that corresponds to the HMI template.
Deviations from this practice require NEORSD approval.
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SECTION 2.9 - INTOUCH APPLICATION
2.9.A - $NEORSD_View (managed InTouch App)
2.9.B - Description
The InTouch application contains windows, dropped ArchestrA instances, InTouch tags, and a
portion of the navigation. This InTouch application is deployed to all of the clients and is run on
every node to ensure the same application is seen by everyone.
2.9.C - Functional Details
• All managed InTouch instances will be derived from $NEORSD_View
• The application on Startup determines the NodeName and Client ID
• After 5 second delay the Overview Screen is displayed
2.9.D - Condition Scripts
• $Inactivity Warning – reference Application Security within for details
• $Inactivity Timeout – reference Application Security within for details
• NewScreen – provides permission to InTouch tag Perm_Value if you are in the
required plant area to operate the targeted equipment on the HMI
2.9.E - Data Change Scripts
• $AccessLevel – Closes Top Hide Banner if Logged off.
• $Minute – Opens the ALARM SCREAMER if correct location and active alarm
• Galaxy:ENG_ESDAP.Redundancy.Identity – refreshes alarm query when engine
failover for Easterly
• Galaxy:ENG_SSDAP.Redundancy.Identity – refreshes alarm query when engine
failover for Southerly
• Galaxy:ENG_WSDAP.Redundancy.Identity – refreshes alarm query when engine
failover for Westerly
• GoToScreen – displays specific windows when monitored bit active
• $OperatorName – On Log off returns correct site menu bar
• MyPrinter – Sets the window printer
2.9-F - QuickFunctions
• GoBack – navigation button
• GoForward – navigation button
• PrintScreen – sets the area of InTouch to be printed
• PushStack – navigation button
• ScreenData – sets remote references
• LoadWindowBanners – Sets location based on the node
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2.9.G - InTouch System Windows
Below are a few of the types of windows included in the Wonderware base program, others are
added as the system evolves.
• System Large Upper Band Window
• System Small Upper Band Window
• System Footer Window
• Hierarchical Name = $NEORSD_View
• Derived from = $InTouchViewApp
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SECTION 2.10 - GENERAL CODING PRACTICES
Native InTouch or ArchestrA button commands, object animation, macros, events, etc should be
used to perform HMI functions. When using scripts the following practices apply to InTouch,
System Platform and ArchestrA Graphic scripts.
Note: “Logic” should be done in the PLC. The HMI should not be calculating values, or making
decisions based upon multiple inputs. All logic outside of basic scripting must be in the PLC.
2.10.A - Scripting Code Comment Guidelines
When available, make use of the native comment capabilities of the software development
environment. To enhance readability make use of upper and lower-cases when commenting.
2.10.B - Scripting Code Headers
Each written code module should contain a script header unless the script itself is basic in nature
using standard COTS functionality. When possible, create a header per the standard indicated
below and contained in the supplied developers Galaxy:
• Module Name
• Author name including Company Name supplying the code module
• Brief description of the module function
• Revision history
• Date the module was changed
• Name of the person making the change
• The example below shows a typical Script header
{'***************************************************** Revision History ********************************************************
'Module Name: Script Name
'Author: Michael R Nicolosi (RoviSys)
'Description: Enter a meaningful description that summarizes the functionality (purpose) of the script
'History:
'Rev By
Date Work Order Modification
'1.0 Michael Nicolosi (RoviSys) dd-Mmm-YY Initial Release Creation of Script
'
'**********************************************************************************************************************************}
Note: When the script has multiple trigger types the default location for the Standard Code
Header is in the first one used.
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2.10.C - Scripting Code Structure Practices
• Large scripts should be separated into smaller functional elements with each major
part commented to indicate what it is doing.
•
Show nesting structures clearly by making use of multi-line IF THEN ELSE coding
practices.
•
Use consistent indentation to show nesting structures clearly. For example make use
of multi-line IF-THEN-ELSE and For-Next loops.
•
If in-line comments are used make sure they line up to the right of the executable
code.
•
Add a blank line between after the header, after variable declarations, and above and
below nested structures (IF-THEN_ELSE, For-Next etc.)
2.10.D - Dead Code
Good engineering practice is to avoid dead code. Dead code is defined as code that is resident in
the program but cannot execute. Comments are not considered dead code.
2.10.E - ArchestrA Device Object Instances
All ArchestrA Object Instances must be created from the appropriate ArchestrA Device Object
Template. Reference NEORSD Standard Object Library User Manual for the list of available
object templates and design details.
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2.10.F - Window Naming Convention
The Wonderware InTouch Window names are limited to 32 characters and will be named to
reflect the site, building, process area, and equipment in the following manner.
[Site][Area]_[Process]_[Equip][Train][Parallel]_ [Equip][Train][Parallel]_[Display]
Section 1.5 Point Tag Naming Convention
Point Tag
Description
Component
Site
Plant or Site Designator
S, E, W, C
Process/Equip
Process
Area
Code
Number
Process or Equipment
Designator.
Train
Process Train Number
Parallel
Parallel
equipment
designator
Up to a 12 character
description
for
the
display type.
Area
Display
Standard Reference
S= Southerly, E=Easterly, W=Westerly, C=Collections
Part II Section 9.1 – two digit numeric code designating
the process area
Refer to Part IV Section 7 – Process, Equipment, and
Parameter Abbreviations for suggestions
Process train number. Not required to use “1” unless
“2” or more exists
Alphanumeric character for multiple equipment
operating in parallel
Optional field – eliminate if running out of characters.
Typical examples include: Overview, Detail, Status,
Maint, Setpoint, NAV (for navigation) and Trend
Note: repeat the [Equip][Train][Parallel] portion of the description as necessary to define the
screen.
Example:
S47_INC2_CNT_Overview
S = Southerly WWTP
47 = Process Area #47 (incineration)
INC = Incinerator
2 = Train 2
CNT= Centrifuges
Overview = Display type; no parallel equipment noted as it is an overview screen.
S47_INC2_CNT2A_Detail
S = Southerly WWTP
47 = Process Area #47 (incineration)
INC=Incinerator
CNT = Centrifuge
2 = Incinerator Train 2
A = first centrifuge on train
Detail = Display type; a more focused display includes the parallel designator.
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Section 2.11 - Display Guidelines
2.11.A - General
• Display window information is to be consistent in presentation especially when
multiple copies exist on process lines or trains.
• In general the layout of the windows should follow the process and logically align
with the physical equipment to the extent of being easily understood by an operator.
• Fonts used must be consistent and follow the text guideline section of this standard
OR must be pre-approved by NEORSD.
• Display windows must be free of typographical errors or graphical discrepancies.
2.11.B - Common
• Windows will contain only information from one building unless it is an overview
window
• Window backgrounds will all be the same color (silver) unless a deviation is preapproved.
• ALL animated objects on the window displays must come from the NEORSD
Standard Object Library.
• Standard title bar exists on each window
• Standard Large Upper Band is viewable always
• Standard Footer is viewable always
• DO NOT develop graphical elements that are hidden (not viewable in development
mode) in WindowMaker. USE visibility functions available in WindowViewer
(runtime environment).
• Window development resolution is 1280 x 1024
2.11.C - Lines
• Lines depicting process piping are static and mimic logical representation of the
process.
• When possible it is preferred for process piping flow to enter the screen from the left
and exit on the right.
• It is preferred that process piping not cross over, however, this is not always practical.
When process lines do cross over (without joining) they must not interest visibly and
break the vertical line only.
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2.11.D - Text Guideline
•
•
•
Do not use periods to denote abbreviations
Window heading are to be centered and contain both the building number and system
name
Informational text is black
Information Type
Color
Font
Size
Window Header
White
Arial, Bold
16
Title / Heading
Black
Arial, Bold
12
Detail Label
Black
Arial, Bold
10
To/From piping button labels
Black
Arial, Bold, Italic
11
2.11.E - Pipes (InTouch vs ArchestrA)
• Process piping is not dynamic
• Standard piping size is set to 5 points
• Standard Process Colors
Pipe Contents
Potable Water
NPW
Seal Water
Steam
Drain
Vent
Sanitary Waste
Air
Fuel Oil
Natural Gas
Influent
Effluent
Chlorine
Hypochlorite
Bisulfite
Waste Pickle Liquor
Ferric Chloride
Acid
Lime
Polymer
Other
Centrate
Supernatant
Sludges
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Color
Blue
Aqua
Aqua
White
White
White
White
Lime
Orange
Orange
Gray
Gray
Yellow
Yellow
Dark Yellow
Purple
Pink
Purple
Purple
Fuchsia
Peach
Black
Bronze
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Examples:
•
Process piping arrows
o Use arrows to indicate direction of flow
o Use arrows to indicate process flow entering or leaving the display window and
include text to indicate source or destination.
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2.11.F - Standard Static Process Symbols
All developed windows must use static process symbols contained within the NEORSD library
(graphic toolbox).
2.11.G - Locations
ArchestrA object templates / Custom Window / Toolbox
2.11.H - Common Symbols
*Insert screenshots of each approved symbol set – in progress.
Section 2.12 - Standard Symbols
2.12.A - Locations
Reference the NEORSD Standard Object Library User Manual.
2.12.B - Common Features
• Symbols change color to indicate equipment status
• Red indicates running or a valve or gate is fully opened
• Green indicates stopped or a valve or gate is fully closed
• Yellow indicates equipment malfunctioning
• Dark Grey indicates information is not available
• Text / Numbers display NaN
• Red status boxes (text) appear when non-alarm process conditions occur
• Yellow status boxes (text) appear when an alarm condition is active
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Section 2.13 - Windows
2.13.A - Adding New Windows
• Windows shall be developed from the NEORSD provided window templates which
feature site specific coloring.
• To make a new window open one of the template windows, right click in the
windows menu and select new. When asked if you want to keep the existing scripts
select yes.
Window Properties
• Window Type = Replace
• Frame Style = None
• Title Bar and Size Control = Unchecked
• X Location = 0
• Y Location = 65
• Window Width = 1280
• Window Height = 699
• Window Color = Grey (Right Column, 4th one down on standard palette)
Window Scripts
• Condition Type – On Show
Screen_Name = "<InTouch Window Name";
CALL ScreenData();
NewScreen = 1;
perm_value = 0;
•
Condition Type – On Hide
PreviousWindow = Screen_Name;
Navigation
Direct Screen navigation buttons are not used
2.13.B - Navigation
Navigation will be derived from an ArchestrA toolbar object which will contain all of the
windows. The tabs on the bar will be organized by process, train, etc. There will be three bars
(Easterly, Westerly, and Southerly) and each bar will only be visible for graphics associated with
that facility.
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2.13.C - Site Specific – Southerly
• Southerly Wastewater Treatment Screen Template
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2.13.D - Site Specific – Easterly
• Easterly Wastewater Treatment Screen Template
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2.13.E - Site Specific – Westerly
• Westerly Wastewater Treatment Screen Template
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SECTION 3 - ControlLogix Programming Conventions
Section - 3.0 - Introduction
The conventions outlined below have been compiled from Rockwell’s Logix5000 Controllers
Common Procedures document (Jan. 2010) and good engineering practice standards developed
in conjunction with the NEORSD. These conventions are designed to promote consistency and
familiarity in controller logic layout across ControlLogix and CompactLogix systems installed
within the NEORSD.
3.0.A - General Programming
All programming should follow good engineering practice. This document identifies standard
tasks, programs and routines, as well as general principles to be used in all ControlLogix
programming. Additionally, it is required that program logic be grouped by process area or
location. Programs shall be descriptively named and thoroughly annotated.
The District reserves the right to request name changes to program Tasks and Routines for
general conformity.
Section 3.1 - Firmware Revision
3.1.A - Controller Firmware Revision
New system installations shall use the latest controller firmware revision approved by the
NEORSD. Integrators must contact the District for the appropriate controller firmware prior to
logic development.
3.1.B - Control Module Firmware Revision
In addition to the controller firmware, at a minimum, communication bridge modules
(ControlNet, Ethernet, DeviceNet, etc.) and other high level function modules shall be flashed
with the highest level firmware revisions compatible with the specified controller firmware.
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Section 3.2 - Controller Naming
The controller name will reflect the process area/building location of the actual PLC (see table in
Part II, Section 9.1 for list of process numbers).
The PLC name will follow the format:
[Site][Area]_[Process][Train]X
Where,
[Site] is the site location of the PLC; S=Southerly, E=Easterly, W=Westerly
[Area] is the two digit code for the process area of the PLC. Refer to Part II Section 9.1 for a list
of process area codes.
[Process] is the description of the process or primary equipment being controlled by the PLC.
Refer to Part IV Section 7 for a list of standard abbreviations.
[Train] is the number associated with the equipment train (1, 2, 3, etc), when applicable.
“_CMN” may be used when multiple trains use a common PLC for auxiliary controls.
X is the alphabetical sequence (A, B, C, etc) for parallel pieces of equipment associated with the
train, when applicable.
Example: S57_CNT1A, for Southerly building 57, train 1, the first centrifuge.
S47_ICE, for Southerly building 47, incinerator common equipment controls.
Also, the PLC program file name should match the PLC name. Using the first example above,
the ControlLogix file name would be S57_CNT1A.acd.
Section 3.3 - Controller I/O
3.3.A - I/O Distribution
I/O is arranged to concentrate related inputs or outputs on single cards so that an I/O card failure
will affect only one or two pieces of equipment, i.e., all start/stop/run/fail signals for a given
pump are on the same card. However, spare or backup equipment shall be entirely wired to
separate I/O cards to avoid losing both pieces of equipment if there is an I/O card failure.
Thorough annotation is required for I/O rack numbers as part of the program documentation.
3.3.B - I/O Electronic Keying
I/O modules will have the electronic keying set to “Compatible Keying”.
Communication modules (CNBT, EN2T, etc) will have the electronic keying set to “Exact
Match” to ensure correct firmware revision is installed, which can effect operation of the system.
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3.3.C - I/O Module and Remote Rack Naming
Each module must be assigned a unique description to aid in identifying the hardware.
The naming convention for modules is defined as:
R#S#_[Rockwell Module Type]
Where,
R# = Rack number
S# = Slot number
[Rockwell Module Type] is the common acronym taken from the Rockwell Module part
number.
Examples:
R0S4_IB16 = a 1756-IB16 module in local rack 0, slot 4.
R2S7_OF6CI = a 1756-OF6CI (isolated current) module, in rack 2 slot 7.
R0S5_EN2T = a 1756-EN2T module in Rack 0, slot 5. This is only applicable when connected
to an HMI network. See naming convention below for remote IO racks.
R1S15_MOD = a generic (third party) module, such as Prosoft Modbus communication card.
The naming convention for a module that links to remote I/O racks (CNB or ENB) is defined as:
[RackLocation]_Rack#
Where,
[RackLocation] = a 2 or 3 letter designator for the process area or equipment associated with the
remote rack. Note: one PLC may have remote racks in different process areas.
Rack# = Rack number as assigned in I/O Configuration
Examples:
INC_Rack1 = the second logical rack (Rack 0 is the first rack), located in the fluidized bed
incinerator area
DW_Rack2 = the third logical rack, located in the dewatering area
3.3.D - I/O Usage in Logic
Module-Defined controller tags shall be referenced in the controller logic within I/O mapping
routines. These routines are designed to provide a single location within the logic where all I/O
tag status and values are updated once per program scan to prevent inputs from changing during
scan. This is commonly known as buffering I/O. Details in configuring I/O mapping routines
are provided in subsequent sections of this document.
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Section 3.4 - Controller to Controller Communication
3.4.A - Message Instructions
Controller to controller communication is permitted over the control network through use of
message instructions. Preference shall be made to discrete I/O signals for the use of interlocking
and control of process points deemed critical or hazardous.
Message instructions offer the following benefits:
• Ability to establish new connections to another controller without taking either controller
offline or having to reschedule network
• Programmatically start/stop communications based on events or sequences
• Ability to buffer I/O connection
See section 3.10 for additional guidance on implementing messaging instructions.
3.4.B - Produce/Consume
Produce/Consume communication between controllers should not be used unless a governing
need is present and written approval has been given by NEORSD. Programmers should
standardize on message instructions based on comparable performance and added flexibility as
compared to the produce/consume method.
Section 3.5 - Controller Tags
3.5.A - Tag Naming
Tag naming is explained in detail under Part II Section 1.9.
3.5.B - Tag Scope
All tags communicating with the HMI or OIT must use controller scoped tag formatting. Tags
not expected to be linked with the HMI may be program scoped.
This means that the AOIs used in the ContorlLogix program to communicate with the
Wonderware object instance need to be controller scoped.
3.5.C - Aliasing
Tag aliasing is not permitted due to limitations in manipulating and readdressing aliased tags
online.
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3.5.D - User-Defined Data Types (UDTs)
General UDT development, for non-HMI/OIT interface logic, is unrestricted and may be freely
used at the programmer’s discretion. UDT usage should be thoroughly annotated, with
comments provided in the UDT description field, as well as the UDT member description fields.
Program logic that includes tag interfaces to the HMI or OIT should always use the appropriate
AOI when possible. Exceptions are only allowed when an existing AOI cannot fulfill the
program requirements. The user must review the application with the NEORSD representative
and receive permission to deviate from AOI usage. When under contract, the RFI procedure
shall be used for UDTs intended for HMI interface.
UDT tag instances are subject to applicable tag naming standards.
Section 3.6 - Task Structure
3.6.A - Task Usage
All logic routines should be organized within periodic tasks within the controller. Periodic logic
execution increases performance, in particular controller to HMI communication, by freeing up
processor overhead.
Event based tasks are permitted but are generally discouraged unless required for a particular
application. Event tasks restricted from use within redundant configurations
Any usage of continuous tasks must be approved by NEORSD.
3.6.B - General Periodic Tasks
Creation of periodic tasks should be kept to a minimum (6 or less) as required by the controlled
process or area. Programmers should attempt to organize area logic within programs and
routines, as opposed to within individual tasks.
The periodic task execution rate should be set to allow ample time for program execution
without burdening the processor. Programmers should frequently monitor and adjust the
execution rate based on the task time.
Each periodic task must be set with a priority from 1 to 15, with 1 representing the highest
priority. It is recommended that each task be set with a unique priority.
3.6.C - PID Control Task
The periodic task for executing setpoint control and PID based algorithms will be called
“PID_Control”. Default Rate = 1 sec, and the Priority = 1.
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3.6.D - I/O Mapping Task
The periodic task for executing the I/O mapping (including messaging) and alarming logic will
be called “IO_Mapping”. Default Rate = 100 msec and Priority = 4.
3.6.E - Process Control Task
The periodic task for the executing the process control and device drivers will be called
“Process_Control”. Default Rate = 200 msec and the Priority = 8.
3.6.F - Miscellaneous Logic
The periodic task for executing any non-specific device or process code will be called
“Misc_Logic”. Default Rate = 200 msec and the Priority = 13
3.6.G - General Event Tasks
There are currently no standard event based tasks.
3.6.H - Unscheduled Programs and Inhibited Tasks
Following system commissioning, all logic not actively being scanned or no longer required shall
be deleted from logic. This includes but is not limited to logic contained within inhibited tasks
and unscheduled programs.
Programmers should not programmatically inhibit or uninhibit tasks.
Section 3.7 - Standard Program Structure
3.7.A - General
The term “Program” is the Logix5000 designation given to the “folder” which hosts various
logical routines. Programs reside under a specific task.
Programs shall be used to organize the logic by process area or system function. Program names
should be intuitive and consistent with area or equipment naming conventions used throughout
the PLC code, as well as HMI/OIT development.
3.7.B - PID Control Programs
Programs shall be created under the PID_Control task for organizing the PID loop control logic.
The program names shall consist of a prefix referencing the process area or equipment, followed
by “_PID). Examples include: “Incinerator1_PID”, “Centrifuge_Pumps_PID”, etc.
3.7.C - Process Control Programs
Programs for process area or equipment control shall be created under the Process_Control task.
The program name is not standardized, but should be consistent with area and equipment naming
used throughout the PLC code.
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3.7.D - I/O Mapping Program
Under the IO_Mapping task, create program areas that align with the type of IO associated with
PLC. These programs shall be used to consolidate the logic routines that move source I/O data to
an internal PLC tag. This includes physical I/O as well as networked I/O.
The majority of projects will include program folders called “Analog_IO”, “Digital_IO”,
“Message_IO”. There may also be networked IO such as ControlNet_IO, DeviceNet_IO, and
Modbus_IO.
3.7.E - Miscellaneous Alarms
Under the Misc_Logic task, create a program area called “Misc_Alarms” for alarms not directly
associated with a physical IO point, such as OIT alarm triggers.
Section 3.8 - Standard Routine Structure
3.8.A - General
RSLogix5000 allows the use of ladder diagram, function block diagram, sequential function
chart, and structured text routines within the logic. Preference to ladder diagrams and function
block diagrams shall be made, followed by sequential function charts when deemed appropriate.
No logic or configuration shall be written in structured text without prior approval from the
District.
3.8.B - Main Routine
Each program folder must contain a ladder routine named “Main” as the main routine. The
purpose of the main routine is to govern the flow of the program. The JSR instructions shall be
used to reference all other logical routines in the PLC program. No other logic is permitted in the
main routine.
It is permitted to condition the JSR with logic to enable or disable the scanning of a particular
routine. An example would be the case of using the First Scan bit to run initialization logic.
3.8.C - I/O Mapping Routines
All control I/O, whether physical or network based, should be organized within I/O mapping
routines in which the I/O value from the module or otherwise defined tag is “mapped” to a local
tag for use within the remainder of the program. These routines provide a central location for all
I/O referenced within the controller and assist programmers in assigning and changing I/O.
3.8.D - Analog I/O
All physical analog inputs and outputs should be referenced within individual analog I/O
routines. Routines shall be separated by module, and follow a naming standard that references
the module rack/slot location as well as signal direction (input or output).
Examples:
R0S4_Analog_Input
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R1S5_Analog_Output
R1S1_Analog_IO (for modules with both input and output channels)
Routines will contain IO mapping and scaling logic when necessary.
Analog Input
All ControlLogix analog input scaling shall be performed in the module configuration. For
CompactLogix or other cases where scaling cannot be performed within the module
configuration, analog scaling will be done in the PLC logic.
Scaling in the module should reflect the engineering units. If multiple units are required in the
PLC code (such as RPM and % speed), the second unit range will be scaled in logic.
Unused analog inputs should be disabled in the module configuration to prevent unnecessary
alarms.
The NEORSD Analog AOI object may be used to move the module value into a controller tag
location and display the value on the HMI. See NEORSD Standard Object Library User Manual
for details on AOI usage.
Use of the Analog AOI object is generally recommended but not always required. For example,
if the input is not displayed or is manipulated before being displayed on the HMI, the
programmer is free to buffer the signal in another manner.
Analog Outputs
Analog output values used within the program shall be scaled as engineering units of percentage
(0-100%). If further scaling is needed it should be performed within the I/O mapping routine
using CPT or similar functions.
The I/O module configuration will be set for 0-100% to final output signal (ex: 4-20ma).
The NEORSD library does not make use of a standard AOI for analog output handling.
Typically, moving the value of a PLC global tag to the output module (via MOV instruction in
ladder, or INPUT/OUTPUT RERENCE direct link in function block) is all that is required.
Analog Alarming
Analog alarms associated with input scaling are generated in the Analog AOI. Other methods of
analog alarming are permitted, but the resultant alarm output must use a NEORSD AOI to be
annunciated in the HMI.
3.8.E - Digital I/O
All physical digital inputs and outputs should be referenced within individual digital I/O
routines. Routines shall be separated by module, and follow a naming standard that references
the module rack/slot location as well as signal direction (input or output).
Examples:
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R0S5_Digital_Input
R1S7_Digital_Output
R1S6_Digital_IO (for a module with both inputs and output channels)
Routines will contain IO mapping and scaling logic when necessary.
Digital Inputs
The NEORSD Discrete AOI object may be used to move the module value into a controller tag
location and display the value on the HMI. See NEORSD Standard Object Library User Manual
for details on AOI usage.
In the case where multiple inputs exist that are common to a signal device (i.e. valve limit switch
inputs and local/remote indication), the inputs may be directly mapped to the device AOI
(Valve_Discrete for example). If the input is required to be annunciated on the HMI or OIT
individually, then it will need the Discrete AOI as well.
Digital Outputs
The NEORSD library does not make use of a standard AOI for digital output handling.
Typically, moving the value of PLC global tag to the output module (via XIC/OTE pair in
ladder, or INPUT/OUTPUT RERENCE direct link in function block) is all that is required.
Digital Alarming
Alarms associated with the state of a digital input are generated in the Discrete AOI. Other
methods of digital alarming are permitted, but the resultant alarm output must use a NEORSD
AOI to be annunciated in the HMI.
In the case that an alarm is ‘active-low’ (i.e. the field input is normally ‘1’ and the alarm is active
when the input signal goes to ‘0’), ensure that the active value is inverted to ‘1’ within the PLC.
This is applicable to safety signals such as emergency-stop switches. Within the Wonderware
HMI, all alarms are expected to be “active-high” for ease of troubleshooting.
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3.8.F - Network I/O
For non-rack-mounted I/O that reside on high level network protocols, such as valves and motors
on DeviceNet, Modbus, etc., separate routines should be created to house their specific I/O.
Routines should be segregated by scanner module rack/slot location as well as by network port
or channel name (A/B, etc.).
Examples:
R0S4_DeviceNet_A
R0S5_Modbus_A
R0S5_Modbus_B
Network IO routines should contain mapping logic for all IO within that particular network port
or channel. This includes both analog and digital, both inputs and outputs.
3.8.G - Message I/O
All tag values passed through message arrays should be separated from other I/O into message
specific I/O mapping routines. An individual routine is required for each controller whose data
is obtained via a message instruction. Message routines should be named by applying the prefix
“MSG_” to the paired controller’s name. An example would be “MSG_S47_INC1”.
All messaging should be performed over Ethernet. Messaging over a DeviceNet network is not
permitted.
See section 3.10 for more messaging details and examples.
3.8.H - General Alarms
Analog alarm functionality is handled in the Analog_IO routines, using the appropriate AOI.
Similarly, alarming from digital input values are generated in the Digital_IO routine using the
Discrete AOI. All other alarm logic shall be located near related logic or grouped within
routines under the “Misc_Alarms” program. Typically this will include alarm logic that is
shared by both the HMI and OIT.
PanelView alarm triggers will be grouped in a routine called “PanelView_Alarms” under the
“Misc_Alarms” program. It is permissible to place alarm logic limited to the PanelView within
this routine.
All alarms will be generated in the PLC in the form of discrete (alarm active/not active) signals.
The programmer should not anticipate using alarm features typically available in the HMI.
Additionally, the PLC logic will be programmed such that the alarm condition occurs on “true”
(Alarm when discrete = 1); no conditioning of the alarms are permitted in the HMI.
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3.8.I - PID Loops
Individual PID routines shall be created under the corresponding PID program. Routine names
shall consist of the specific control loop name. Naming shall be consistent throughout the PLC
code.
Examples include:
Incinerator1_Air_Flow
Boiler1_Level
3.8.J - Process Control Routines
Process control routines shall be created under the corresponding Process Control program area.
Routine names shall consist of the specific device name. Process names shall be consistent
throughout the PLC code.
Section 3.9 - Initialization Logic
3.9.A - General
System critical variables and control modes shall be initialized at controller startup. The
preferred method is to utilize the processors “First Scan” bit, but other techniques are allowed.
It is the contractor’s responsibility to review the specific process needs for initialization logic
with the District, on every project.
3.9.B - Initialize Routine
Include a routine named “Initialize” under each program area that requires initialization logic.
Condition this routine in the “Main” routine using the controller’s S:FS bit (system first scan).
Note that the NEORSD AOI library objects utilize pre-scan routines that initialize each AOI
prior to executing the AOI main logic.
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Section 3.10 - Message Instruction Guidelines
3.10.A - General
Messaging is hosted in the local controller and can only execute CIP Data Table Read command.
Programs should never write data to another controller without written authorization from
NEORSD.
All messaging should be performed over Ethernet. Messaging over a DeviceNet network is not
permitted.
In a redundant processor system, the messaging must take into account the dual network
pathways. If one network is down, the messaging will continue over the remaining pathway.
A failed message command should automatically reset itself after an appropriate amount of time.
Messaging should not be used to communicate HMI signals to a PLC. If a direct Ethernet
connection to the PLC is not available to the HMI, contact your District representative.
3.10.B - Organization
Messaging logic should be organized into two program areas:
IO_Mapping Message_IO
• Use individual routine for each PLC.
• Organize instructions into common order: map Send data (data to be read by other PLC),
map Receive data.
• Data is organized into DINT and REAL, requiring separate message instructions, per
PLC.
Misc_Logic  Message_Control
• MSG_Control routine should contain the logic for regulating the execution of the MSG
commands, as well as error handling.
• Use separate routines for each PLC being messaged.
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3.10.C - Peer Messaging Guidelines
This section provides further details regarding messaging structure, data format and code
examples.
Peer to peer communications for PLC’s within the NEORSD facilities should satisfy the
following requirements:
• Use MSG instructions hosted in the local controller to execute CIP Data Table Read
o MSG instructions should only “read” (CIP Data Table Read) data from other
PLCs; never “write”.
o Produce/Consume not used
• Organize MSG data mapping routines under IO_Mapping
o Individual routine for each PLC
o Organize instructions in common order: map Send data, map Receive data
o Data organized in DINT and REAL arrays, requiring separate MSG instructions
per PLC
• Organize MSG control logic under Misc_Logic routine
o Logic includes a sequencing operation to regulate MSG execution
o Execute messaging over both network pathways simultaneously
o Monitor watchdog from target PLC (looping 60 second time). Take corrective
action if watchdog value goes stale.
o Automatic reset of failed messages
o Provide network status (primary/secondary) and comm status (ok/fail, based on
watchdog) on OIT
• Tag Naming should follow a consistent pattern
o The Discrete objects associated with alarming, which may be displayed on the
OIT and HMI, must follow a specific format to ensure they are unique within the
Wonderware Galaxy.
o The internal tags associated with the message command and data arrays should be
consistent and follow the examples provided in this document, and ultimately the
District Automation Standard.
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Typical Messaging Architecture
PRIMARY CONTROL SYSTEM NETWORK
SECONDARY CONTROL SYSTEM NETWORK
Local PLC:
Target PLC:
DISTRIBUTED I/O
DISTRIBUTED I/O
Primary Pathway
Secondary Pathway
Message Data Tags (DINT/REAL) and MSG tags
Data array tag name format:
MSG instruction tag name format:
[DIRECTION]_[PLC_NAME]_[DATATYPE]
SEND or RCVD
DINT or REAL
[PLC_NAME]_[DATATYPE]_[PRI/SEC]_MSG
PRI or SEC
Target PLC name
Target PLC name
DINT or REAL
Message Alarm Tags
Alarms are generated from the Primary and Secondary MSG error bits, as well as the Watchdog
fault (both primary and secondary MSG errors). Discrete objects must be used to map these
alarms into the OIT and HMI. Since the alarm tags are a part of the Wonderware galaxy, each tag
must be unique. Use the following format when naming these tags:
[Local_PLC_Name]_[PRI_MSG_FLT]_[Target_PLC_Name] (ex: 47_INC1_PRI_MSG_FLT_S47_ICE)
[Local_PLC_Name]_[SEC_MSG_FLT]_[Target_PLC_Name] (ex: S47_INC1_SEC_MSG_FLT_S47_ICE)
[Local_PLC_Name]_[WatchDog_FLT]_[Target_PLC_Name] (ex: S47_INC1_WatchDog_FLT_S47_ICE)
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Sample OIT Message Status Display
Discrete object templates are used for all
Primary, Secondary, and Watchdog
alarms.
Locate under the MAINTENANCE area
within the OIT application.
Alarms need to be added to the OIT
alarm summary.
The AOI object should be configured for
alarming.
HMI graphics can be developed in
similar fashion (Watchdog timeout is not
necessary as it cannot be seen at the HMI
if both networks are down).
Message Example
Local PLC (S47_INC1) is the PLC to receive data from the target PLC (S47_ICE).
Secondary message instruction includes same source and destination tags, but has different
Ethernet IP addressing.
S47_INC1 Message Tags
Send Data
SEND_S47_ICE_DINT[x]
SEND_S47_ICE_REAL[x]
Receive Data
RCVD_S47_ICE_DINT[x]
RCVD_S47_ICE_REAL[x]
MSG Instruction Tags
S47_ICE_DINT_PRI_MSG
Source: SEND_S47_INC1_DINT[x]
Dest: RCVD_S47_ICE_DINT[x]
S47_ICE_DINT_SEC_MSG
S47_ICE_REAL_PRI_MSG
Source: SEND_S47_INC1_REAL[x]
Dest: RCVD_S47_ICE_REAL[x]
S47_ICE_REAL_SEC_MSG
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In addition to receiving data from the ICE PLC, the
S47_INC1 will be “sending” data to the ICE PLC.
Mapped DINT or packed BOOL values in S47_INC1,
for S47_ICE to read
Mapped REAL values in S47_INC1, for S47_ICE to read
This is the data the local MSG commands pulled from the
target PLCs.
Destination tag in S47_INC1 for DINT or packed BOOL
values, read from S47_ICE
Destination tag in S47_INC1 for REAL values read from
S47_ICE
In the local PLC. A set of instructions for Primary and
Secondary pathways, for both DINT and Real.
Primary message to read S47_ICE DINT array
Source tag, as created in the target PLC
Destination tag, as created in local PLC
Secondary message to read target PLC DINT array
Primary message to read target PLC REAL array
Source tag, as created in the target PLC
Destination tag, as created in local PLC
Secondary message to read target PLC REAL array
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Code Example
The following code example includes logic within PLC S47_INC1, to message between PLC
S47_ICE. A second PLC (S57_SH) is also configured, but the logic is not shown, since the
messaging principle is represented with one example.
The Main program routines are not shown in the images below. It is understood that all Main
routine utilize JSR instructions to execute the program logic. See Section 3.8.B for additional
details.
Map data to “Send” (read by other
PLC) and Read in the IO_Mapping
Task area.
Message Logic is located under
Misc_Logic task area
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Section 3.11 - General Coding Guidelines
3.11.A - Commenting Logic
All logic routines must be clearly commented in the rung description.
The first rung of a routine should summarize the overall routine function, as well as the logic
found on the rung.
When similar functionality is being repeated, a brief description clarifying the relative
differences from the fully comment rung is acceptable.
All changes made after commissioning must be commented. Post commissioning comments
require the following:
• Date of change
• Initials of person making the change
• Company that employs the person making the change
• Reason and description of change
Example: 12/02/10 – JBZ – RoviSys – Added an example to the standard.
3.11.B - Indirect Addressing
Indirect addressing in the form of passing input parameters between subroutines and accessing
values within array elements should be minimized within the program as much as possible. The
use of the instruction “FOR” to loop through a subroutine repeatedly should similarly be
avoided. If indirect addressing is used, it must be thoroughly documented.
3.11.C - Subroutine Nesting
Programmers shall limit the depth of ladder subroutine level jumps to 2 (MainRoutine 
Subroutine1, Subroutine1  Subroutine2).
Programmers should not use JSR instructions to jump up or back out of routines. Use the RET
instruction instead.
3.11.D - Output Instructions
Output instructions (OTE, MOV, Timers, etc.) must be located to the right of all input
instructions located on the corresponding rung or branch. Output instructions should not be
located in between or to the left of any other input instructions.
Multiple outputs per rung are permissible. Programmers should make use of rung branches to
organize and condense multiple outputs, to aid in viewing rungs.
3.11.E - Function Block Sheets
Function block subroutine should be contained on a single sheet when possible to ease
review/troubleshooting. When multiple sheets are unavoidable, the programmer should organize
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the sheets such that each sheet contains a set of logic pertaining to a single area or piece of
equipment.
Programmers should adjust the sheet size to accommodate grouped logic within a single sheet.
Programmers shall also provide adequate spare sheet space for future logic.
3.11.F - Simulation of Logic
Adding code to simulate normal operating conditions, for testing purposes, is permitted. Please
segregate programs and routines of simulation logic in order to aid removal prior to
commissioning.
Simulation shall only be enabled through the PLC programming software, not from OIT or HMI.
3.11.G - Fault Resets
There shall be no automatic resetting of faulted hardware, such as VFDs. The PLC logic will
create a fault alarm that is annunciated at the OIT and the HMI. Typically, software faults should
be programmed so that the hardware fault must be cleared first before the software fault will
clear.
3.11.H - Forced Logic
Use of forced logic for normal operation is not permitted. Forcing logic during testing is
acceptable but all forces must be removed when the system is placed in service.
The “forces enabled” status will be made available on the HMI as part of the normal execution of
the PLC_Status object.
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3.11.I - Alarm Horn and Light Acknowledging
Alarm logic may latch alarm annunciation (horn or light) but not the alarm. To silence the horn
and stop a flashing light, the following tags should be created in the PLC:
PV_ACK (BOOL)
PV_SILENCE (BOOL)
The PanelView Plus 6 will manipulate for reset or alarm action.
PLC
PV_ACK will be toggled by the PanelView Plus 6 any time an alarm is acknowledged or the
“Ack All” button is pressed on the Alarm Summary.
PV_SILENCE will be toggled by the PanelView Plus 6 any time the “Silence” button is pressed,
an alarm is acknowledged, or the “Ack All” button is pressed on the Alarm Summary.
OIT
The following configuration must be added to the base PanelView Plus 6 applications:
Alarm Setup:
Triggers Tab
Check “Use ack all value:” 1
“ACK” = {::[PLC]PV_ACL}
Advanced Tab
“Hold Time (ms):” 1000
SILENCE = {::[PLC]PV_SILENCE}
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Section – 3.12 - General Control Mode Philosophy
3.12.A - Local Control Modes
All equipment will have local manual control capability at or near the associated equipment.
Equipment that can also be controlled remotely by the PLC will have a Local-Off-Remote
selector switch at that piece of equipment to select control location. If the selector switch is in the
Local position, the local manual control will be enabled and the remote control and PLC control
will be disabled.
3.12.B - Remote Control Mode
When the Local-Off-Remote selector switch for the equipment that can be controlled remotely is
in the Remote position, the remote control and PLC control will be enabled and the local manual
control (except for stop push buttons) will be disabled. Where multiple remote control locations
are available such as OIT and HMI, both controls are available simultaneously with no priority
given to one or the other. The OITs are intended for use in maintenance.
In some cases, there is more than one level of remote control. In the case of a
VFD driven pump or blower, for example, local control is provided by a Local Control Station
(LCS) at or near the piece of equipment as the VFD is usually remote from the equipment. The
remotely located VFD then acts as a first layer of remote control. The OITs and HMls, together,
form the second layer of remote control. To separate the two layers of remote control, a switch,
labeled VFD/PLC, shall be provided on the panel containing the VFD.
Operation
a. When the Local/Off/Remote switch on the LCS is in the Local Mode, the equipment
shall be controlled via start and stop pushbuttons on the LCS.
b. When the Local/Off/Remote switch on the LCS is in the Remote Mode and the
VFD/PLC switch at the VFD is in the VFD mode, start/stop and speed control will be
manually adjusted by the operator at the VFD.
c. When the Local-Off-Remote switch on the LCS is in the Remote Mode and the
VFD/PLC switch at the VFD is in the PLC mode, the PLC will be allowed to control the
equipment based on control values entered by the operator. The PLC will control the
equipment in either a PLC Manual or a PLC-Auto mode of operation, as selected by the
operator at the HMI.
1) PLC-Manual Control: The PLC-Manual mode of control requires operator action at
the HMI to change the operating status of the piece of equipment.
2) PLC-Auto Control: PLC-Auto control allows the PLC to control the equipment
based on operator-entered Setpoints and measured values (using PID algorithms).
3) Out-of-service: In this mode, selected at the MCS, the equipment is considered
unavailable by the control system. Indicate at the MCS equipment that is out of
service and manage alarms accordingly.
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3.12.C - Control Mode Functions
Remote Manual control: It shall be possible for the Operator to interrupt any sequence, loop, or
automatic operation and operate the same manually through the operator workstation or OIT.
Protective Interlocks: Equipment protective, hardwired interlocks shall remain in effect in all
control modes.
Section 3.13 - Add On Instruction (AOI)
3.13.A - Usage
The NEORSD has created a library of Add-On Instructions to be used for program development.
Any communication between the PLC and the HMI or OIT must utilize a District approved AOI.
Refer to NEORSD Standard Object Library User Manual for a complete list of the current AOI
and configuration instructions.
It is expected that the contractor will populate all parameter fields of the NEORSD Object AOI,
regardless of contract requirements. Any exceptions must be reviewed with the NEORSD project
manager.
UDT (user defined data type) are only allowed when an existing AOI cannot fulfill the program
requirements. The user must review the application with the NEORSD representative and receive
permission to deviate from AOI usage.
Additional AOI usage, in either ladder or function block, is not restricted and may be freely used
at the programmer’s discretion. AOI usage must be thoroughly annotated. AOI tag instances are
subject to applicable tag naming standards.
3.13.B - Source Protection
Source protecting AOI is prohibited without approval from NEORSD. For any protected AOI,
logic must be must be fully viewable by the District and a function description outlining
performance must be provided.
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SECTION 4 - PANELVIEW PLUS 6 PROGRAMMING CONVENTIONS
Section 4.0 - Introduction
This section outlines the Allen-Bradley PanelView Plus 6 programming standards in place for
NEORSD. These conventions are designed to promote consistency and familiarity in design and
layout across all OIT’s installed within the District.
The practices outlined below have been compiled from good engineering practices promoted by
Rockwell Automation and those developed by the District.
Note: It is the District’s intention to have the PLC/PanelView OIT Ethernet network separate
from the PLC/HMI control Ethernet network. This requires multiple Ethernet modules in the
PLC rack.
Section 4.1 - Software
Integrators shall request the type and version of Rockwell software currently in use at the District
for PanelView application development. The software should be patched with the most recent
patch rollup available from Rockwell prior to application development.
Section 4.2 - Standard PanelView Framework
4.2.A - Overview
The District maintains a base PanelView project to provide integrators with a starting point in
creating new applications. The base project contains example displays that use the screen size,
font, display colors, etc, and other application attributes that adhere to the standard as described
in the sections below.
Note that the District standard is for PanelViews with key pads and touch screens.
The base PanelView project also contains a set of Global Objects that provide the foundation for
PanelView application development. The Global Objects templates are designed to simplify
PanelView application develop as well as promote consistency on HMI interfaces both between
systems and across PanelView and Wonderware platforms.
4.2.B - Standardized Objects and Functions
The PanelView Global Objects standard library contains object symbols that may be dragged and
dropped into PanelView HMI graphics. These symbols are already configured for animation,
textual message displays, and faceplate links for operator interaction. It is the application
programmer’s responsibility for selecting the correct Global Object from the library and
configuring that particular instance for ControlLogix tag and description attributes.
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Section 4.3 - Project Settings
4.3.A - PanelView Application Name
The PanelView application name should incorporate the site, building, process, and equipment
information as defined below:
[Site][Area]_[Process][Train][X]_OIT[Alpha]_[FTversion]
Where:
[Site] – Site designator for Westerly (W), Southerly (S), or Easterly (E), Collections (C).
[Area] – Two digit process area code as provided by the District. Refer to Section 9.1 for
a listing of the process area numbers.
[Process] – The character reference to the process or equipment area being monitored
and/or controlled as defined in Part IV Section 7.
[Train] is the number associated with the equipment train (1, 2, 3, etc), when applicable.
_CMN may be used when multiple trains use a common PLC for auxiliary controls.
[X] is the alphabetical sequence (A, B, C, etc) for parallel pieces of equipment associated
with the train, when applicable.
[Alpha] – Unique alpha character identifying PanelViews that otherwise would have the
same tag descriptor. Characters must be assigned alphabetically. The alpha code is not
required for process or equipment with only a single PanelView Plus 6 terminal.
[FTversion] – The version of FactoryTalk View ME used to create the application. Use
“p” for the decimal point. Ex: Version 6.1 would be expressed as 6p1.
Examples:
S57_CNT1A_OIT_6p1 (The PanelView Plus6 terminal associated with Southerly
building 57, train 1, first centrifuge, version 6.1)
S47_WSC3_OIT2_6p0 (The PanelView Plus 6 terminal associated with Southerly
building 47, wet scrubber, train 3, panel 2, version 6.0)
4.3.B - Project General Settings
The project window size must correspond to the target PanelView Plus 6 (or current series)
device.
FactoryTalk View ME automatically sizes the display to match the window size of the target
PanelView Plus 6 (or current series) device designated in the project settings. The default
window sizes are as follows:
PV Plus 6, Model 700
PV Plus 6, Model 1250
PV Plus 6, Model 1500
640x480
800x600
1024x768
A custom window size for the application is not permitted.
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4.3.C - Project Runtime Settings
The default project runtime settings within FactoryTalk Studio ME should be used for project
development. Specifically, projects must follow the format below:
•
•
•
•
Disable title bar (uncheck)
Disable border (uncheck)
Project window position of Top: 0, Left: 0
Enable auto logout
o Inactivity Period: 10 minutes
o Uncheck Return to Graphic on Logout
4.3.D - Internal Clock Synchronization
In order to synchronize time displays across control network interfaces, the PanelView Plus 6’s
internal clock should be synchronized with the internal clock of the main PLC the application
communicates with.
PanelView Plus 6 synchronization is achieved by configuring the following Global Connections
within the application:
Connection
Remote Date and Time
Tag or Expression
({[PLC]CLOCK[3]}==0)
Remote Year
Remote Month
Remote Day of Month
Remote Hour
Remote Minute
Remote Second
{[PLC]CLOCK[0]}
{[PLC]CLOCK[1]}
{[PLC]CLOCK[2]}
{[PLC]CLOCK[3]}
{[PLC]CLOCK[4]}
{[PLC]CLOCK[5]}
Description
Sets clock on rising edge
trigger at 12:00 am
Year GSV Value
Month GSV Value
Day GSV Value
Hour GSV Value
Minute GSV Value
Second GSV Value
The default Global Connection Maximum update rate of 1 second should be maintained.
CLOCK refers to a DINT tag array of length 7 within the PLC. The array should be populated
through the use of the GSV WALLCLOCKTIME function within logic.
4.3.E - Other Global Connections
No other Global Connections are required for standard PanelView Plus 6 applications. Consult
with the District prior to configuring additional Global Connections settings within the
application.
4.3.F - MER Files
Only the current machine edition runtime file (.mer) may be stored on the PanelView. All older
versions of the application should be removed and archived in the Districts Asset Centre.
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Section 4.4 - Display Development
4.4.A - Display Type
“Replace” type displays shall be used for depicting process flow, measurements, and status.
Replace type displays consume the least amount of memory and provide a simplified mechanism
for closing the prior screen.
All onscreen functionality will be depicted within a single opened Replace type screen. This
includes local display time, logged in user indication, the graphical depiction of the process, real
time tag values and control measurements, and screen navigation. Common functionality will be
repeated on each Replace type screen, as needed.
“On Top” display types shall be used for faceplates and other overlay graphics as required by the
project. With the exception of faceplate graphics included as part of the standard template
library, On Top display types should be limited within the project.
“On Top Cannot Be Replaced” display types shall not be used without prior approval from the
District.
4.4.B - Display Name
Refer to the diagram in section 4.4E for additional clarity. Display names shall take the
following format:
[AREA#][DISP#] - [AREA/PROC] - [DISPLAY]
Where:
[AREA#] – Arbitrary 2-digit number (not related to tag naming area), that groups
common screens together in the application. For applications with only a single area, this
value should be 01. Valid ranges are from 01 to 39.
[DISP#] – Unique number referencing a particular process or display within the area.
Valid range is 1 through 9.
[AREA/PROC] – Up to a 10 character description for identifying the common grouping
of screens referenced by the [AREA#] field. Use the abbreviations in Part IV Section 7
when applicable.
[DISPLAY] – Description identifying the display graphic referenced by the [DISP#]
field.
Note: if the description exceeds 20 characters try shortening it by using standard
abbreviations shown in Part IV Section 7.
Examples:
021 – FW – OVERVIEW
022 – FW – SOFTENERS
041 – DSP – OVERVIEW
044 – DSP – DSP STPTS
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The display title shown in the upper left hand corner of each display shall use the same display
name as outlined above.
4.4.C - Color Standards
The following is a general guideline on the use of coloring object’s and animation:
Background
Header Background, Nav and
Other Display Buttons
Process Piping
Status
Animations
(On/Off/Event/Fault)
Numeric Display, Numeric Input
Disabled
Numeric Input Enable
Label and Desc Text
Inanimate, Unknown, or Static
Objects
Light Gray (Use Base Project Default)
Medium Gray (Use Base Project Default)
Reference figure below.
Reference District Standard Section Part II Section 1.1
Light Gray Background, Black Font
White Letters, Black Background
Black
Medium Gray, or Gray Shaded/Gradient as provided in
FactoryTalk View ME Libraries
Process Piping
Standard process piping colors are shown below:
The District maintains an OIT graphic that contains the standard process piping colors, sizes, and
process arrows for use with OIT applications. Developers should make use of these standard
objects when at all possible.
Process piping should run either horizontal or vertical and connect at right angles. Piping drawn
diagonally should be avoided.
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4.4.D - Font
Labels, descriptions, numeric values, and other textual displays should all be a small sized yet
clearly readable font, Arial style, black, and bold by default. For model 1250 and model 1500
PanelView Plus 6 (or current series) terminals, font sizes should be between 10-12. For
PanelView Plus 6, Model 700, size 8-10 is acceptable.
For titles or headings within the graphic display or other text that requires greater attention, the
text size may be sized slightly larger and underlined.
For navigation and other functional buttons, the text size 8 font, Arial style, black, and bold by
default.
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4.4.E - Navigation
PanelView applications should follow the navigation standard set forth within the base project
example. The following diagram illustrates the standard “Row/Column” navigation approach:
MAIN
A3
D1
A4
D1
A1
D2
A3
D2
A4
D2
A1
D3
A3
D3
A4
D3
A1
D1
A2
D1
A5
D1
Log
in
Log
out
A3
D4
AREA 2
DISPLAY 1
AREA 1
DISPLAY 1
D2
D1
D1
D3
...
D1
AREA 5
DISPLAY 1
...
AREA 1
DISPLAY 2
D1
D2
ALARM
SUMMARY
D3
Hist
Stat
ALARM
HISTORY
AREA 1
DISPLAY 3
Hist
D2
D3
...
D1
Stat
Each “Column” of buttons represents a process area or equipment. The first “Row” button
navigates to the specific area. The subsequent row buttons indicate what additional screens exist
within that specific area. Only the first row of buttons has navigation functionality. The other
screens are accessible from the bottom button bar, only after navigating to the overview screen
(or similar), from the Main menu screen.
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Note: The last column of buttons should be reserved for any system configuration or system
settings screens. These screens will be accessible only when the user is logged in with proper
security.
Main
Each PanelView Plus 6 project will contain a main screen configured as the initial starting
graphic when the application boots. The Main screen will contain buttons to navigate to an
overview or primary screen for each process area in the project. Additionally, the Main screen
will contain login/logout functionality, as well as a “Shutdown” Button to access the terminals
native configuration mode for those logged in with proper access rights.
Display Areas
All displays within a configured area will contain a similar navigation bar placed at the bottom of
the screen. The bar will contain a button to navigate back to the main screen as well as buttons
to navigate to all configured screens within that area. In order to navigate to a different area, the
user will have to navigate back to the main screen.
It is encouraged to use an area overview screen as the first display for the area.
With the exception of calling faceplate and other On Top display types, no other “Goto Display”
Buttons may be placed within the graphic.
Alarm Summary, History, and Status
All screen displays must contain a link to the alarm summary screen. This makes the alarm
summary accessible from anywhere within the application. The alarm summary screen shows
the currently active and unacknowledged alarms. Closing the alarm summary screen returns the
user back to the last viewed process display screen.
From the alarm summary, the user may navigate to the alarm history screen and, if logged in
with proper rights, the alarm status screen. Closing these screen returns the user back to the
alarm summary, from which they can return back to the last viewed process display.
Keypad Usage
K-Keys are reserved for full-page navigational purposes within the application. All navigation
buttons must be assigned a unique K-Key designator for navigating through the application using
the keypad.
The navigation button label should contain the assigned K-Key, preferably on the second line of
the label, in parentheses.
F-Keys are reserved for operation type functions such as device START/STOP, mode selection,
setpoint entering, etc. The top row of F-Keys should be used to open the objects on the screen,
while the second row of F-Keys should be reserved for actions on the object faceplate. This
technique will prevent accidental “double-clicking” of a key, which could result in undesired
action.
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K-Key assignments should only be used for navigation of full screen displays. Faceplate and
other popup displays shall use F-Key assignments.
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Key Assignments
The assignment of K- and F-Keys to objects within an application follows a standardized
approach that must be observed in order to promote consistency across PanelView Plus 6
models. Since the number and location of similar keys differs between PanelView Plus 6 model
sizes, the keypad assignment for routine operations (return to Main, close faceplate, etc) will be
assigned a key based on that key’s location on the face of the PanelView and not necessarily by a
consistent key number. The following diagram illustrates this standard approach:
Top Right-Hand Side K-Key
Return to Main
Allen-Bradley
PanlView Plus XXXX
2nd ToTop Right-Hand Side K-Key
Alarm Summary
Misc. Right-Hand Side K-Keys
Reserved for Standard Object
Library faceplate tab navigation
Left-Hand Side K-Keys
Application specific
process display navigation
Top Row F-Keys
Application specific
equipment operations
and selections
Bottom Row F-Keys
Reserved for Standard Object
Library faceplate operations
Bottom Right K-Key
Exit for all faceplate
and popup displays.
The following tables list standard key pad functions for each PanelView Plus 6 type:
PanelView Plus 6, Models 1250/1500
Key Assignments on Typical Process Area Display
Key
Function
K1-K10
Navigation between displays within a process area (application specific)
K11
Return to Main Screen, accessible on all screens
K12
Displays Alarm Summary Screen
K13-K14 (No function)
K16-K19 Navigation between faceplate tabs on active faceplate
K20
Closes faceplates, Diag., Info., Alarm pop-ups, or any On-Top display
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F1-F10
F11-F20
Equipment operations/selections, device faceplate (application specific)
Faceplate operations on standard library objects
Key Assignments on Main Screen Functions
K1-K10
Navigation between process areas (application specific)
K11
(No function)
K12
Displays Alarm Summary Screen
K13
Displays Trend Overview Screen (Navigation to Trend Area)
K14
Displays Maintenance Overview Screen (Navigation to Maintenance Area)
K15
PanelView Configuration Access (Requires Login)
K16-K20 (No function)
F1
User Login
F2
User Logout
F3-F20
(No function)
For PanelView Plus 6, Model 1250 and 1500 terminals, integrators typically will assign K1-K10
and F1-F10 to objects within their specific application. For screens with more than 10 objects
requiring assignment, keys F11-F20 may be used, starting with F11. Assigning other keypad
assignments to objects should be avoided as they are reserved for standard functions.
PanelView Plus 6, Model 700
Key Assignments on Typical Process Area Display
Key
Function
K1-K6
Navigation between displays within a process area (application specific)
K7
Return to Main Screen, accessible on all screens
K8
Displays Alarm Summary Screen
K9-K11
Navigation between faceplate tabs on active faceplate
K12
Closes faceplates, Diag., Info., Alarm pop-ups, or any On-Top display
F1-F5
Equipment operations/selections, device faceplate (application specific)
F6-F10
Faceplate operations on standard library objects
Key Assignments on Main Screen Functions
K1-K6
Navigation between process areas (application specific)
K7
(No function)
K8
Displays Alarm Summary Screen
K9
Displays Trend Overview Screen (Navigation to Trend Area)
K10
Displays Maintenance Overview Screen (Navigation to Maintenance Area)
K11
PanelView Configuration Access (Requires Login)
K12
(No function)
F1
User Login
F2
User Logout
F3-F10
(No function)
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For PanelView Plus 6, Model 700 terminals, integrators typically will assign K1-K6 and F1-F5
to objects within their specific application. For screens with more than 5 objects requiring
assignment, keys F6-F10 may be used, starting with F6. Assigning other keypad assignments to
objects should be avoided as they are reserved for standard functions.
Illustration of Key Assignments
The following diagram illustrates an example PanelView Plus 6, Model 1250 graphic display and
depicts standard K and F-Key assignments:
Custom Faceplate
K20 exit. All controls on
faceplate use bottom row
F-keys.
Custom Faceplate Nav
Use top row F-Key for
faceplate navigation
button. Faceplate
navigation buttons to be
placed in main display
PanlView
area with other objects.
Standard Nav
Use right-side K-keys for
standard navigation (main,
alarm). These are included in
base program.
Allen-Bradley
MAIN (K11)
K1
(F5)
K2
ALM (K12)
Faceplate Nav
Plus 1250
K11
K12
Custom Faceplate
K13
K3
K4
K5
K6
(F11)
Button/Num Entry
(F12)
Button/Num Entry
(F13)
Button/Num Entry
(F14)
Button/Num Entry
(F1)
START
(F2)
STOP
K14
K15
K16
(F3)
K7
K17
Exit (K20)
(F4)
K18
K8
K19
K9
K10
DSP1
(K1)
DSP2
(K2)
DSP3
(K3)
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
K20
Standard Objects
Use top row F-Keys for
all standard object
assignments. This
includes push buttons,
numeric entry, and
faceplate navigation
buttons for motors,
valves, etc.
Display Navigation
Use left-hand side KKeys for standard full
size display navigation
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4.4.F - OEM Screens
Integrators may include displays that provide information critical for system testing and
commissioning (such as tuning PID loops). These displays should use an [AREA] assignment of
30 and an [AREA/PROCESS] description of “OEM”.
Examples include:
301 – OEM – Setpoint Limits
302 – OEM – Drive Settings
OEM displays are never used for normal operation and any pertinent information must be made
available on District accessed displays. Access to OEM screens must be removed after
commissioning.
Other than the naming convention above, OEM graphics are not subject to the District standard.
Standard navigation to OEM screens is provided in the base application and should be used when
possible.
Section 4.5 - Tag References and Usage
4.5.A - Direct Reference Tags
All references to ControlLogix tags made within a project shall be made using Direct (Device)
Reference.
Direct reference tags are used to maximize the runtime performance of tag read/write operations,
to minimize tag memory consumption, and to remove the added HMI layer for configuration of
basic display read and write operations.
4.5.B - HMI Tags
HMI tags in general should not be used to link application elements (tag displays, trends, data
log models, etc.) with ControlLogix controller tags. Instead, direct reference tags should be used
wherever possible.
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Section 4.6 – Security
New applications submitted for approval shall have a single Default user account set with full
privileges. Additional user accounts and passwords will be configured onsite, during the
commissioning of the system, from a District provided engineering laptop. This will insure that
the correct user accounts and associated District FactoryTalk Directory security settings will be
deployed.
The remainder of this section describes the final security settings. Contractors should develop
applications/screens that will make use of the security privileges and account profiles detailed
below. Refer to section 4.6.C for security usage instructions.
4.6.A - User Groups and Accounts
A standard set of user groups will be provided by the District for use within each PanelView Plus
6 application. One of more accounts under each group may be assigned to each PanelView
application. The standard user groups are listed below:
•
•
•
•
•
Default (View Only)
Operator
Maintenance
Supervisor
Configure
4.6.B - General Account Privileges and Restrictions
The bulleted list below outlines security codes and runtime account privileges for each user
group that should be anticipated for the final application.
Default (View Only) – Security Code A
• Can view all process monitoring screens
• Unable to enter values or change setpoints
• Unable to open control object faceplates
• Unable to acknowledge alarms
• Unable to access PanelView terminal settings
The default account is provided for leaving the PanelView in a safe and secure state. The user
can navigate through the application and monitor process values. They are unable to control
equipment or setpoints or otherwise impact the running process.
Operator – Security Code A, B
• Can view all process monitoring screens
• Able to open and operate object faceplates for the purpose of device mode selection and
manual control
• Able to view and acknowledge configured alarms
• Unable to enter values or change setpoints for process control
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•
•
Unable to enter or change configuration type values on faceplate objects (e.g. alarm
limits)
Unable to access PanelView terminal settings
Operator accounts are provided for basic operator control and monitoring. Operators may
typically view all process and faceplate data, but are unable to change process configuration type
values. When operator set point manipulation is required, it must be provided at this security
level.
Maintenance – Security Code A, B, C
• Can view all process monitoring screens
• Able to open and operate object faceplates for the purpose of device mode selection and
manual control
• Able to view and acknowledge configured alarms
• Able to access maintenance specific screens for diagnostic information
• Unable to enter values or change setpoints for process control
• Unable to enter or change configuration type values on faceplate objects (e.g. alarm
limits)
• Unable to access PanelView terminal settings
Maintenance accounts take all of the operator’s abilities and add access to maintenance specific
screens for extended diagnostic features.
Supervisor – Security Code A,B,C,D
• Can view all process monitoring screens and additional process setpoint/limit screens as
configured
• Able to open and operate object faceplates for the purpose of device mode selection and
manual control
• Able to view and acknowledge configured alarms
• Able to enter values and change setpoints for select process control points
• Unable to enter or change configuration type values on faceplate objects (e.g. alarm
limits)
• Unable to access PanelView terminal settings
Supervisor accounts have limited added privileges over operator accounts. Supervisors can
access and change select process control setpoint limits that are deemed appropriate by PLC
programmers.
Configure– Security Code A,B,C,D, E
• Can view all configured screens
• Able to open and operate all provided objects on control faceplates
• Able to view and acknowledge configured alarms
• Able to enter values and change setpoints for all provided process control points
• Able to enter and change configuration type values on faceplate objects (e.g. alarm
limits)
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•
Able to access PanelView terminal settings
Configure accounts have unrestricted access to the PanelView runtime application. Configure
accounts should be held only by District engineers for runtime editing of template block
operation as well as configuring the PanelView Plus terminal settings.
4.6.C - Configuring Security Access
The Global Object Template library is designed to meet most application runtime security needs.
For example, during runtime, template objects with faceplates require Operator or equivalent
privileges to access. Faceplate configuration type settings similarly require Configuration level
access privileges.
For additional security needs, the application developer should make an attempt to segregate
restricted controls or settings on screens accessible only to those with proper security levels. The
use of visibility animation on navigation buttons is the preferred method by the District.
Visibility animation should be evaluated using the CurrentUserHasCode( ) function.
The Security Code field part of Display Settings should not be used as a means to restrict access
to displays. The default setting (* - all users) should be retained for consistency.
4.6.D - Account Login/Logout
All user accounts with the exception of View are password protected and require the user to
provide both a username and password when logging in.
The “Logout” option on the main screen will logout the current user and login to the default
(View only) account. In order to switch to an operator, supervisor, or configure account, the user
will have to select the “Login” option on the main screen.
New PanelView projects are prohibited from providing other user account control functions
other than the default login/logout provided on the Main screen in the base project. Set password
functions
for
logged
in
users
during
runtime
is
prohibited.
4.6.E - Auto Logout
Each PanelView Plus 6 application should be configured for automatic logout after a period of
inactivity. This setting is configured in the Project Settings dialogue and is referenced in Section
04.3.C - Project Runtime Settings of this document.
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Section 4.7 – Alarming
4.7.A - Trigger Type
All configured alarm messages within the PanelView application shall use the Bit trigger type as
opposed to the Value and LSBit methods. The Bit trigger method aids in reducing the number of
alarm trigger tags, which can lead to optimized communications overhead and memory usage
within the running program.
4.7.B - Trigger Tag
Developers should use one or more ControlLogix DINT tags to serve as a Boolean array for
alarm trigger. Applications should be configured using a single trigger tag of type DINT or
DINT array (DINT[X], where X is the array length) named:
PV_ALARM
Where advantageous the developer may choose to group alarms into one or more areas, with
unique trigger tags with the following format:
PV_ALARM_[AREA]
Where [AREA] represents the area or equipment pertaining to the alarms in the trigger.
4.7.C - ControlLogix Trigger Routine
PanelView alarming should be organized in the ControlLogix processor within one or more
dedicated routines. Ladder routines are preferred.
Alarming bits on the trigger tag should not be latched, but instead only held active as long as the
alarm is active. Alarm messages within the PanelView application are be generated when the
trigger bit value transitions from 0 to 1.
No PanelView to PLC acknowledgment handshaking should be used.
4.7.D - Trigger Label
The label for each trigger tag should carry over the name of the trigger tag name defined in
ControlLogix for consistency and simplicity.
4.7.E - Message Guidelines
Each alarm trigger should generate a unique message that is concise yet descriptive. Process
area and equipment naming shall remain consistent across OIT, PLC and HMI platforms. For
PanelView applications with similar alarm sets for more than one set of equipment or process
train, the alarm message shall be prefixed with the equipment or train number to be followed by
the alarm in the message.
Several alarm message examples are shown below for a raw water softener skid with three units:
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“Softener #1 Conductivity High”
“Softener #2 Conductivity High”
“Softener #2 Differential Pressure High”
“Softener #3 Conductivity High High”
Use of embedded variables in the alarm message shall not be used.
Alarm messages must fully match across both the HMI and OIT displays as well as the
comments provided in the tag description in the PLC.
In general, the PLC programmers shall decide the alarm message, place the message as part of
the bit field comment of the alarm tag, and provide the same alarm message for OIT and HMI
developers to configure.
4.7.F - Advanced Settings
Default values for the advanced alarm settings as defined within the base PanelView project shall
be used.
The default advanced alarm settings values are detailed below:
Display
[Alarm] (PV default)
History
128
Hold Time (ms)
250
Max Update Rate (seconds)
1
Optional Connections
(None)
Prior approval from the District is required before a specific application may deviate from the
advanced settings.
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4.7.G - Alarm Displays
The default alarm display shall be used in all PanelView applications. This display, by default,
will open a pop-up when a new alarm is generated and displays an alarm banner object.
Active and/or unacknowledged alarms may be viewed from the Alarm List object displayed on
the Alarm Summary graphic, which is accessible via navigation from all screens.
A historical log generated alarms is accessible from a similar Alarm List object displayed on the
Alarm History graphic. This graphic is accessible from the Alarm Summary graphic.
The Alarm Status graphic displays configuration and diagnostic information regarding the alarm
setup for the PanelView application. Alarm Status information is only accessible to user
accounts with Maintenance level or higher credentials.
No other alarm objects, including alarm lists or banners, should be created within the PanelView
application.
4.7.H - Alarm Filtering
Alarm filtering should not be incorporated into any alarm object within the PanelView Plus 6
application. The Alarm Summary, Alarm History, and Alarm Status displays by default must
show all configured alarms.
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Section 4.8 – Trending
4.8.A - Trend Areas
Areas 10 – 19 of the standard PanelView application are reserved for historical trend screens.
This area provides a central location where any user can navigate to view all configured trends
for a given application.
Navigation through the trend screen area follows in a similar manner as process displays
described before. Display 101- Trend Main displays a directory of configured trends screens
from which the user during runtime may navigate between trend areas. When inside a particular
trend area, the user may navigate between trend displays in that area or return to the main trend
directory.
Trend screen naming should follow the standard PanelView display naming conventions outlined
4.4.B. The Area/Process and Display description fields in the display name are up to the
developer’s choosing.
4.8.B - Trend Area Template
Developers should make use the trend template graphic provided with the base PanelView
application for configuring trends within the trend areas. No other process object or other
display information should appear on these screens. Only one trend should appear on each
screen.
4.8.C - Other Trends
Aside from trends configured in the trend area, trends may also be configured and placed on
process displays as required. These trends must use the built in ME Studio trend object, and
should follow trend standard colors and attributes set forth within this document.
4.8.D - Trend Colors
The colors within the example trend in the base project shall be used for all trending with the
application. The color standards are listed below:
Background
White
Text Color
Black
Grid (X,Y axis)
Dark Gray
Pens, in increasing order
(See below)
Pen colors for a single control loop trend shall follow the table below:
Process Variable (PV)
Setpoint (SP)
Control Variable (CV)
Green
Blue
Yellow
For all other trends, use of the default trend object pen colors (in increasing order: blue, light
green, red, magenta, black, dark green, yellow, light blue) is generally preferred. Otherwise, the
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pen colors are at the discretion of the application developer, in which case pen colors may be
chosen to match process line colors, etc. Pen colors shall be chosen that are unique between
pens and are clearly distinguishable against the white background.
4.8.E - Refresh Rate
The maximum refresh rate that may be chosen for a trend is 2 seconds. In general, a refresh rate
of 2 seconds shall be chosen for trending process data. The developer may select a slower
refresh rate based upon the process, the time span, etc.
4.8.F - Trend History
The application should provide historically log all trended values for a period of 12 hours.
4.8.G - Maximum Pens per Trend
The developer shall limit the number of pens per trend to 8 or less.
4.8.H - Other Trend Settings
In general, developers shall try to use the existing trend examples in the base project as a
guideline for configuring trends in their application.
The following list details general trend settings:
GENERAL
Chart Style
Chart Update Mode
DISPLAY
Chart Radix
Data Point Connection
Display Milliseconds
Display Pen Icons
Font
Scrolling
Scroll Mode
Buffer for Extra Data
PENS
Width
Marker
X-AXIS
Display Scale
Display Gridlines
Grid Lines
Y-AXIS
Isolated Graphing
Display Scale
Display Grid Lines
Grid Lines
Scale Options
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Automatic
Decimal
Connect Data Points
Unchecked
Checked
Arial, 8, Bold
Allow
Continuous
2000
1
None
Checked
Checked
4 Major, 0 Minor
Unchecked
Checked
Checked
4 Major, 0 Minor
Select Each Pen On Independent Scale
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Section 4.9 - Data Logging
4.9.A - Number of Models
Applications should include a single data log file to collect all pertinent data. Only one data log
can run at any given time.
Use of data log models is required to provide trend history for all configured application trends.
4.9.B - Maximum Data Points
The maximum data points must be set to achieve a 12 hour history of logged data for all
configured trends.
4.9.C - Logging Path
The system default logging path should be used for all data log models.
4.9.D - Log Triggers
Each log should be set up to trigger periodically at an interval no faster than 2 seconds.
4.9.E - Tags In Model
All tags within the model must be configured as direct reference tags. Tags within the same
model may be polled from more than one PLC. There are no limits to the number of tags within
each model.
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Section 4.10 - IO Diagnostic Screens
4.10.A - Overview
All PanelView Plus 6 applications are required to provide displays depicting PLC hardware
health and status information. These screens are built using standard PLC module diagnostic
global objects distributed by the District to provide maintenance personnel with real time module
channel status and diagnostic information. These screens are designed provide view only
information and are primarily intended for maintenance and troubleshooting activities.
4.10.B - Screen Requirements and Architecture
The following depicts screen quantity and requirements:
Maintenance Overview
The Maintenance Overview display is a single screen that is intended to summarize the
architecture of the viewed PLC system. The display graphically shows the number of and type
of PLC racks, OITs, and network types (Ethernet, Modbus, etc.). Objects on the Maintenance
Overview graphic are static; they are not animated and do not provide status information.
The District standard DIAGNOSTIC library contain symbols specific for generating the
Maintenance Overview display.
PLC Rack Displays
A separate maintenance display should be created for every PLC rack contained within the
architecture. Each display will show a single PLC rack detailing the chassis size, module
configuration, and current module health (OK, FAULT).
The District standard DIAGNOSTIC library contains PLC rack and chassis elements as well as
global object module symbols for use in generating the rack displays. Module symbols require
configuration.
Module Faceplate Displays
Specific module information is provided on faceplates incorporated into the standard
DIAGNOSTIC symbols. Faceplates display module and loop information including
channel state (on/off, analog %), channel faults, device tag (from P&IDs), device
description (from IO list), device units (analog inputs), and other relevant module
configuration settings.
Most diagnostic templates read RSLinx Enterprise and ControlLogix module defined tag data to
gather diagnostic information. Generally no ControlLogix AOI or programming is required.
If the diagnostic template for a specific module is not available in the District’s library, the
contractor shall create a new template, using one of the existing templates as a model.
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4.10.C - Area and Navigation
Areas 20 – 29 of the standard PanelView application are reserved for Maintenance and
Diagnostic type displays. Typically, only one a single area (20) is required for maintenance
screens. The total number of screens will, at a minimum, consist of:
•
•
1 for the Maintenance Overview
1 screen per PLC rack (Processor and Remote IO racks)
The main maintenance screen (200 – MAINTENANCE OVERVIEW) should contain navigation
links to each PLC rack screen.
Use the following display names as applicable:
200 – MAINTENANCE OVERVIEW
201 – MAINTENANCE – RACK 0
202 – MAINTENANCE – RACK 1
203 – MAINTENANCE – RACK 2…
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Section 4.11 - Standard Control Templates
4.11.A - Global Object Templates
All PanelView controls that provide read/write functionality to ControlLogix tags must make use
of the District Standard Global Objects Template library. Each template object is preconfigured
to match on a one-to-one basis with ControlLogix AOI’s.
For a complete list of the objects and instructions on their proper use, refer to NEORSD Standard
Object Library User Manual.
4.11.B - General Usage Requirements
All global template object expressions and animations are pre-linked to the required member of
the corresponding ControlLogix AOI tag. PanelView Plus 6 programmers should not try to
adjust or change field values or animation settings with the template object itself.
Object instances are created using a drag and drop method onto the desired graphic. Each
instance requires at a minimum the following fields, generally presented in the following order:
Discrete Valve and Motor Objects:
Parameter
Field
#1
Tag Address
#2
Tag Name
#3
Device Desc
#4
Keypad
#4-#9
Intlk Desc
Description
PLC tag (direct reference)
Device Tag for display on faceplate
Device/Tag description for display on faceplate
Keypad Assignment for display next to object
Interlock 1 – 5 descriptions for display on faceplate
Analog Objects
Parameter
#1
#2
#3
#4
#5
Field
Tag Address
Tag Name
Device Desc
Eng Units
Keypad
Description
PLC tag (direct reference)
Device Tag for display on faceplate
Device/Tag description for display on faceplate
Units for display on faceplate
Keypad Assignment for display next to object
Discrete Objects
Parameter
Field
#1
Tag Address
#2
State 0 Text
#3
State 1 Text
#4
Fault Text
Description
PLC tag (direct reference)
Text displayed when discrete value is 0 (clear)
Text displayed when discrete value is 1 (active)
Text displayed when fault active
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PID/PIDE Objects
Parameter
Field
#1
Tag Address
#2
Tag Name
#3
Device Desc
#4
Eng Units
#5
Keypad
Description
PLC tag (direct reference)
Device Tag for display on faceplate
Device/Tag description for display on faceplate
Units for display on faceplate
Keypad Assignment for display next to object
Diagnostic Module Objects
Parameter
Field
#1
Tag Address
#2-??
Channel Tag
Description
PLC tag (direct reference, references module tag)
Channel device tag for display on faceplate
4.11.C - Global Object Default Values
The PanelView Plus 6 project should retain the original settings for the Global Object Default
Values as provided in the base project. The required settings are as follows:
LinkAnimation default: Link with expressions
LinkConnections default: True
LinkSize default: True
Retaining these settings will ensure that the global objects work correctly and are used in the
manner that they were intended.
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SECTION 5 - DEVICELOGIX PROGRAMMING
Section 5.0 - Introduction
DeviceLogix Smart Component Technology integrates logic-solving capability into I/O, motor
starters, push buttons, and other control components, providing higher-performance and lowercost distributed control. A DeviceLogix capable device operates as a slave device on a
DeviceNet network. You can enable a logic operation using the DeviceLogix Editor to provide
local control over outputs on a device. These logic operations are limited to:
• Boolean
o AND, OR, XOR, NAND, NOR, XNOR
• Bistable
o RS LATCH, SR LATCH
• Counters / Timers
o UP CTR, UP/DN CTR, PULSE TMR, ON DELAY TMR, OFF DELAY TMR
Section 5.1 - Programming for DeviceNet
5.1.A - General
DeviceLogix is a stand-alone Boolean program which resides within the DeviceNet component.
RSNetworx for DeviceNet is required to program the device with this technology. It is important
to note that the DeviceLogix program will only run if the logic has been enabled, which can be
done within the Logic Editor of RSNetWorx for DeviceNet.
5.1.B - Software
The below software packages are required to enable the DeviceLogix program applications.
• RSNetWorx for DeviceNet
• RSLinx Classic
RSNetWorx for DeviceNet is a 32-bit Windows application program that allows you to
configure DeviceNet devices. Using a graphical or spreadsheet representation of your DeviceNet
network, you can configure all devices on the network.
5.1.C - Revisions
The District requires all new DeviceLogix application programs to use the same version of
RSNetWorx that is currently in use at the NEORSD. Verify with the District project manager
which program version to use before starting any new applications.
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Section 5.2 - Standard Program Structure
5.2.A - Logic Routines
DeviceLogix allows for function blocks or ladder logic programming. However, the District
requires all DeviceLogix programming to be done in ladder logic for ease of maintenance.
5.2.B - Node Address
Each device on a DeviceNet network must have a unique node address which can be set to a
value from 0 to 63. Address 0 is always reserved for the master device (Scanner) and node
address 63 should be left vacant for introduction of new slave devices.
5.2.C - Network Communication Speed
The data rate of all the devices connected to the network is user-configurable, but ultimately
limited by the distance of the DeviceNet cable. For consistency purposes, the network speed
should be set for 125K baud.
5.2.D - Commenting Logic
All RSNetWorx programs must be accurately commented. The first rung comment should
describe the purpose of the logic, with following rungs adding detail as necessary.
Commenting includes all program titles, all program logic, and all program elements.
5.2.E - EDS Files
RSNetWorx for DeviceNet software can access only those DevicNet devices that have been
registered. You must use the EDS Wizard for registering EDS files for unknown devices, as well
as installing EDS files.
The District requires the contractor to supply EDS files for all new devices.
Section 5.3 - Standard Program Naming Conventions
5.3.A - RSNetWorx Program Naming Convention
The RSNetWorx application program will be stored in the District’s FactoryTalk Asset Centre
system. For this reason it needs to follow a standard naming format. The RSNetworx program
name applies to a network of devices, and as such should account for the common name of the
area in which that network exists.
The general convention to be used for any new program should take a “drill down” approach:
Process Area  Network Area  Sequential Numerical Designator
The name must also include a prefix that indicates the NEORSD plant and process area. This
information is provided in Part 2, Section 9 of the automation standard.
The format is represented in the following:
[Plant][ProcessArea]_[Network Area Name]_[Number]
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The network name should provide enough detail to clearly understand what devices are serviced
by the program. Any abbreviations must comply with the NEORSD Process/Equipment
Abbreviation, provided in Part 2, Section 4 of the automation standard.
Example: North MCC #1, Southerly Cooling Water Pump and others, located in the access
building #1. The file name becomes “S02_ North MCC_1”
Where
•
•
•
•
S=Southerly
02 = the process area (access bldg 1), per the lists provided in Part 2, Section 9.
North MCC is the common name of equipment area, and so becomes the network
area name
“1” is the parallel equipment designator, or train number of the device.
See example of the RSNetWorx file name screen shot below, where the file name is being set
through the “Save As” function.
5.3.B - Device Naming Convention
The device name is set under the “General” tab. The device name should be created in a
consistent manner, and provide adequate detail. To aid in this, the following format should be
utilized:
[Equipment Label]_[Device Type]_[Detail Info]
Equipment Label - Physical equipment tag. Use physical location if no tag is available
Device Type – The DeviceNet device; E3 overload, DSA module, etc.
Detail Info – additional details relevant to the device type.
• E3 devices should include the full load amps
• DSA devices should include the details of the I/O
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o Interlocks, permissive, etc
Example: North MCC #1, Bucket D, E3 Plus Overload relay
• Name = Bucket D_E3 Plus_3.5A
o FLA = 3.5A
Example: North MCC #1, Bucket D, DSA I/O device
• Name = Bucket D_DSA_Interlock
o I/O is associated with motor interlocks
It is also recommended that the description field be utilized for additional details. When possible,
the asset number or property tag should be included in the description.
See example of the Device naming in the screen shot below, which is from the RSNetWorx for
DeviceNet program, device properties.
5.3.C - DeviceLogix Program
When creating a DeviceLogix program, all users should fill in the following information:
• Author - Company/Integrator_ Initials
o Example: NEORSD_JS; NEORSD employee John Smith
• Revision - Originating at “1” and going up sequentially. Note: this is not tracked.
• Description - Brief description of process, equipment and function. Include project
number if applicable.
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See example of the DeviceLogix properties screen shot below, which is from the
RSNetWorx for DeviceNet program, device properties, DeviceLogix tab.
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Section 5.4 - Standard Ladder Editor Commenting Conventions
5.4.A - Ladder Commenting
All Ladder Logic rungs must be commented to identify the function/purpose of the rung.
• The first rung of the program should outline the purpose of the overall logic, along
with the function of the first rung.
• The additional rungs must be commented with their specific purposes.
• Each logic element/operand must be commented to identify its purpose.
• Include tag labels when possible.
See example program below.
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